1996 CHRYSLER VOYAGER Service Manual

Fig. 94 Transfer Shaft Gear and (Select) Shim
Fig. 95 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
Fig. 96 Install Transfer Shaft Gear Bearing Cone
Fig. 97 Governor Support Retainer
Fig. 98 Remove Governor Support Retainer Bearing
Cup
Fig. 99 Install Governor Support Retainer Bearing
Cup
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 100 Low-Reverse Band Anchor Pin
Fig. 101 Governor Assembly
Fig. 102 Transfer Shaft Bearing Snap Ring
Fig. 103 Remove Transfer Shaft and Bearing
Retainer Assembly
Fig. 104 Remove or Install Transfer Shaft and
Bearing Retainer Assembly Using Tool L-4512
Fig. 105 Transfer Shaft and Bearing Retainer
21 - 40 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 106 Remove Transfer Shaft Bearing Cone
Fig. 107 Install Transfer Shaft Bearing Cone
Fig. 108 Remove Transfer Shaft Bearing Cup
Fig. 109 Install Transfer Shaft Bearing Cup
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of
the following parts are replaced:
²Transaxle case
²Transfer shaft
²Transfer shaft gear
²Transfer shaft bearings
²Governor support retainer
²Transfer shaft bearing retainer
²Retainer snap ring
²Governor support
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness.
ASSEMBLY
To install transfer shaft, reverse the above proce-
dure.
PARKING PAWL
DISASSEMBLY
ASSEMBLY
To install, reverse the above procedure.
Fig. 110 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
Fig. 111 Checking Transfer Shaft End Play
Fig. 112 Parking Sprag Rod Support
Fig. 113 Support and Bolts
Fig. 114 Parking Pawl, Return Spring, and Pivot
Shaft
21 - 42 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair
of output shaft. Planetary gear sets must be
removed to accurately check output shaft bearing
turning torque.
Fig. 115 Remove Output Shaft Retaining Nut and
Washer
Fig. 116 Remove Output Shaft Gear
Fig. 117 Output Shaft Gear and (Select) Shim
Fig. 118 Remove Output Shaft Gear Bearing Cone
Fig. 119 Install Output Shaft Gear Bearing Cone
Fig. 120 Remove Output Shaft and Rear Annulus
Gear Assembly
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 121 Remove Output Shaft
Fig. 122 Remove Rear Planetary Annulus Gear
Bearing Cone
Fig. 123 Install Rear Planetary Annulus Gear
Bearing Cone
Fig. 124 Install Output Shaft into Rear Planetary
Annulus Gear
Fig. 125 Remove Output Shaft Gear Bearing Cup
Fig. 126 Remove Rear Planetary Annulus Gear
Bearing Cup
21 - 44 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of
the following parts are replaced:
²Transaxle case
²Output shaft
²Rear planetary annulus gear
²Output shaft gear
²Rear annulus and output shaft gear bearing
cones
²Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear
of this section, to determine proper shim thickness.
Check output shaft bearings turning torque,
using an inch-pound torque wrench. If turning
torque is 3 to 8 inch-pounds, the proper shim
has been installed.
Fig. 127 Install Output Shaft Gear Bearing Cup
Fig. 128 Install Rear Planetary Annulus Gear
Bearing Cup
Fig. 129 Install Output Shaft Assembly
Fig. 130 Output Shaft and (Select) Shims in Position
Fig. 131 Start Output Shaft Gear onto Output Shaft
Fig. 132 Holding Output Shaft Gear
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for
differential repair and bearing turning torque check-
ing.
Fig. 133 Tighten Output Shaft Retaining Nut to 271
N´m (200 ft. lbs.)
Fig. 134 Checking Output Shaft End Play
Fig. 135 Checking Bearings Turning Torque
Fig. 136 Remove Extension Seal
Fig. 137 Install New Seal into Extension
Fig. 138 Differential Cover Bolts
21 - 46 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)