1996 CHRYSLER VOYAGER cooling

(13) Remove the power steering fluid return hose
(Fig. 15) from the power steering pump.
(14) Remove the support bracket at the rear of the
power steering pump attaching the pump to the rear
of the engine (Fig. 16).
(15) Remove the 2 bolts mounting the power steer-
ing pump to the alternator/power steering pump and
belt tensioner mounting bracket (Fig. 16).
(16) Remove the power steering pump from its
mounting bracket.
(17) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its mount-
ing bracket. Install the 2 power steering pumpmounting bolts (Fig. 16). Tighten the power steering
pump mounting bolts to a torque of 54 N´m (40 ft.
lbs.).
(3) Install the support bracket attaching rear of
power steering pump to engine (Fig. 16). Tighten the
nut and bolts to a torque of 54 N´m (40 ft. lbs).
NOTE: Before connecting the power steering pres-
sure line to the power steering pump, inspect the
O-ring on the pressure line for damage and replace
if damaged.
(4) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 15). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid low pressure
return hose on the power steering pump low pressure
fitting (Fig. 15).Be sure hose clamps are prop-
erly reinstalled and return hose is clear of all
accessory drive belts.
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 15).Be sure all
hose clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 11). See
Cooling, Group 7 for detailed installation procedure.
(8) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
13).
(9) Install a screw type hose clamp on the power
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 13). This is required
to prevent overheating of the power steering hoses.
(10) When used, properly position the protective
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(11) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(13) Install the accessory drive splash shield (Fig.
14).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
Fig. 15 Power Steering Hoses At Power Steering
Pump
Fig. 16 Power Steering Pump Mounting
NSSTEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)

(10) Remove the serpentine accessory drive belt
from the engine (Fig. 20). See Cooling, Group 7 for
detailed removal procedure.
(11) Remove the power steering fluid supply hose
coming from the remote fluid reservoir, from the fit-
ting on the power steering pump (Fig. 21). Drain off
excess power steering fluid from hose.
(12) Remove the power steering fluid pressure line
(Fig. 21) from the power steering pump. Drain excess
power steering fluid from tube.
(13) Remove the power steering fluid return hose
(Fig. 21) from the power steering pump. Drain excess
power steering fluid from tube.
(14) Remove the support bracket at the rear of the
power steering pump attaching the pump to the rear
of the engine (Fig. 22).
(15) Remove the 3 bolts mounting the power steer-
ing pump to the alternator/power steering pump and
belt tensioner mounting bracket (Fig. 23).(16) Remove the power steering pump from its
mounting bracket.
(17) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its mount-
ing bracket. Install the 3 power steering pump
mounting bolts (Fig. 23). Tighten the power steering
pump mounting bolts to a torque of 54 N´m (40 ft.
lbs.).
(3) Install the support bracket attaching rear of
power steering pump to engine (Fig. 22). Tighten the
nut and bolt holding the strut assembly to bracket
and the intake manifold stud to a torque of 54 N´m
(40 ft. lbs).
Fig. 20 Serpentine Drive Belt And Routing
Fig. 21 Power Steering Hoses At Power Steering
Pump
Fig. 22 Power Steering Pump Support Bracket
Fig. 23 Power Steering Pump Mounting Bolts
NSSTEERING 19 - 17
REMOVAL AND INSTALLATION (Continued)

NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 21). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 21).Be sure hose clamps are prop-
erly reinstalled.
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 21).Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 20). See
Cooling, Group 7 for detailed installation procedure.
(8) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
18).
(9) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 18). This is required
to keep the power steering hoses from becoming
overheated.
(10) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 18).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(11) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(13) Install the accessory drive splash shield (Fig.
19).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING FLUID RESERVOIR TO PUMP
SUPPLY HOSE
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 24).
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove power steering fluid supply hose rout-
ing clip (Fig. 25) from stud in strut tower.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 24 Fluid Supply Hose At Power Steering Fluid
Reservoir
Fig. 25 Power Steering Fluid Hose Routing Clip
19 - 18 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION
POWER STEERING PUMPÐ2.5L DIESEL
NOTE: The power steering pump is mounted below
the fuel pump on the left side of the engine. The
vehicle should be raised on a hoist to access the
pump from below.
REMOVAL
(1) Remove serpentine drive belt. Refer to Group 7,
Cooling System, for procedure.
(2) Remove power steering pump pulley. Use a hex
wrench to secure the power steering shaft while
removing the pulley bolt with a box wrench. (Fig. 2)
CAUTION: Do not use an impact wrench to remove
the pump pulley ± this can cause rear pump seal
damage. Do not secure power steering shaft with a
wrench on the coupling to the A/C compressor ±
this can cause rear pump seal damage.
(3) Remove coupling bolts (2) from A/C compressor
side of coupling.
(4) Loosen A/C compressor bolts and separate com-
pressor from bracket. Do not disconnect A/C hoses.
(5) Remove bolts (2) securing the power steering
pump to the power steering bracket.
(6) Disconnect power steering pump supply hose at
the pump and drain fluid.
(7) Disconnect power steering pressure hose at the
steering gear assembly.
(8) Remove power steering pump.
INSTALLATION
(1) Install pump on engine.
(2) Tighten pump bracket bolts to 47 N´m (35 ft.
lbs.).(3) Reverse the above procedures in steps 8
through 1 to complete installation.
(4) Add power steering fluid and perform Power
Steering Pump Initial Operation.
Fig. 2 Power Steering Pump Pulley Removal
Fig. 3 Left SIde Motor MountÐVM DIesel
19 - 2 STEERINGNS/GS
SERVICE PROCEDURES (Continued)

GENERAL INFORMATION
31TH TRANSAXLE
NOTE: Safety goggles should be worn at all times
when working on these transaxles.
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
in Diagnosis and Tests.
NOTE: Transaxle operation requirements are differ-
ent for each vehicle and engine combination. Some
internal parts will be different to provide for this.
Therefore, when replacing parts, refer to the seven
digit part number stamped on rear of the transaxle
oil pan flange.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
(4) Center distances between the main rotating
parts in these three areas are held precise to main-
tain a low noise level.
(5) The torque converter, transaxle area, and dif-
ferential are housed in an integral aluminum die
casting.The differential oil sump is common
with the transaxle sump. Separate filling of the
differential is NOT necessary.
(6) The torque converter is attached to the crank-
shaft through a flexible driving plate. Cooling of the
converter is accomplished by circulating the tran-
saxle fluid through a remote cooler. There are two
types of coolers used. An oil-to-water type cooler
located in the radiator side tank and/or an oil-to air
heat exchanger. The torque converter assembly is a
sealed unit that cannot be disassembled.
(7) The transaxle fluid is filtered by an internal fil-
ter attached to the lower side of the valve body
assembly.
(8) Engine torque is transmitted to the torque con-
verter then, through the input shaft to multiple-disc
clutches in the transaxle. The power flow depends on
the application of the clutches and bands. Refer to
Elements in Use Chart in Diagnosis and Tests sec-
tion.
(9) The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The drive shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump, and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor of the
final drive (axle) ratio. The shaft also carries the gov-
ernor and parking sprag. An integral helical gear on
the transfer shaft drives the differential ring gear.
The final drive gearing is completed with one of two
gear ratios of 2.98 or 3.19 depending on model and
application.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the dipstick.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle dipstick where it may be mistaken for a
leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
21 - 2 TRANSAXLE AND POWER TRANSFER UNITNS

SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
Type ................Automatic three speed with
torque converter and integral differential
Torque Converter Diameter........241 millimeters
(9.48 in.)
Oil Capacity..............8.6 Liters (18.25 pints)
OilType..........MopartATF PLUS 3 Type 7176
Cooling Method......Water Heat Exchanger and/or
air to oil heat exchanger
Lubrication......Pump (internal-external gear-type
Gear Ratios
Transmission Portion
First Gear..............................2.69
Second Gear.............................1.55
Third Gear..............................1.00
Reverse Gear............................2.10
Pump Clearances
Outer Gear To Pocket.............0.045-0.141mm
(0.0018-0.0056 in.)
Outer Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)
Inner Gear Side Clearance.........0.020-0.046mm
(0.0008-0.0018 in.)Tapered Roller Bearing Settings
Differential Assembly . . .6 to 12 in. lbs. Drag Torque
Output Hub............0to3in.lbs. Drag Torque
Transfer Shaft.........0.002 to 0.010 in. End Play
Overall Drag At Output
Hub.............3to16in.lbs. Drag Torque
Clutch Pack Clearances
Front Clutch (Not Adjustable)........1.27-2.79mm
(0.050-0.110 in.)
Rear Clutch.........0.71-1.10mm (0.028-0.043 in.)
Band Adjustment
Kickdown, Backed Off From 8 N´m
(72 in. lbs.).....................21/4Turns
Low-Reverse, Backed Off From 5 N´m
(41 in. lbs.)......................31/2Turns
21 - 64 TRANSAXLE AND POWER TRANSFER UNITNS

Housing Remover Adapter L-4437
Starter Nut L-4439
Transfer Shaft Remover-Installer L-4512
Bearing Cup Remover L-4517
Special Jaw Set L-4518
Installer L-4520
Bearing Splitter P-334
Cooling System Tester 7700
21 - 70 TRANSAXLE AND POWER TRANSFER UNITNS
SPECIAL TOOLS (Continued)

OPERATION
The gear ratios for the 41TE transaxle are as fol-
lows:
²1stÐ2.84
²2ndÐ1.57
²3rdÐ1.00
²ODÐ0.69
²ReverseÐ2.21
Final Drive Ratio is dependent on which engine
option is selected.
²2.4 Liter: 3.91 FDR
²3.3 Liter: 3.62 FDR
²3.8 Liter: 3.45 FDR
The torque converter clutch is available in 2nd,
direct, or overdrive gear;. The shift lever is conven-
tional with six positions: P, R, N, OD, 3, and L avail-
able. When OD is selected the transaxle shifts
through all four speeds with torque converter clutch
available in overdrive. This position is recommended
for most driving. The 3 position is tailored for use in
hilly or mountainous driving. When 3 is selected, the
transmission uses only 1st, 2nd, and direct gears
with 2nd-direct shift delayed to 40 mph or greater.
When operating in 3 or L positions torque converter
clutch application occurs in direct gear. This
improves transmission cooling under heavy loads. If
high engine coolant temperature occurs, the torque
converter clutch will also engage in 2nd gear. The L
position provides maximum engine braking for
descending steep grades. Unlike most current tran-
saxles, upshifts are provided to 2nd or direct gear at
peak engine speeds if the accelerator is depressed.
This provides engine over-speed protection and max-
imum performance.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with an opening between the
two.
The torque converter fills in both the (P) Park and
(N) Neutral positions. Place the selector lever in (P)
Park to check the fluid level.The engine should be
running at idle speed for at least one minute,
with the vehicle on level ground. This will
assure complete oil level stabilization between
differential and transmission.The fluid should be
at normal operating temperature (approximately 82
C. or 180 F.). The fluid level is correct if it is in the
HOTregion (cross-hatched area) on the oil level indi-
cator.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
the 41TE transaxle. MOPARtATF PLUS 3 (Auto-
matic Transmission FluidÐtype 7176) should be used
to aid in assuring optimum transmission perfor-
mance. Fluids of the type labeled DEXRON II Auto-
matic Transmission Fluid arenot recommended.It
is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transaxle, other than the
fluid listed above. An exception to this policy is the
use of special dyes to aid in detecting fluid leaks. The
use of transmission sealers should be avoided, since
they may adversely affect seals.
DESCRIPTION AND OPERATION
CLUTCH AND GEAR
The transaxle consists of:
²Three multiple disc input clutches
²Two multiple disc grounded clutches
²Four hydraulic accumulators
²Two planetary gear sets
This provides four forward ratios and a reverse
ratio. The input clutch-apply pistons were designed
with centrifugally balanced oil cavities so that quick
response and good control can be achieved at any
speed. A push/pull piston is incorporated for two of
the three input clutches.
21 - 72 TRANSAXLE AND POWER TRANSFER UNITNS
GENERAL INFORMATION (Continued)