1996 CHRYSLER VOYAGER Service Manual

TRANSAXLE DISASSEMBLE
NOTE: Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
(1) Remove input and output speed sensors.
(2) Remove transaxle solenoid pack (Fig. 59).
Fig. 58 Low/Reverse Switch Valve And T/C Limit
Valve
Fig. 59 Remove Solenoid Pack
Fig. 60 Remove Oil Pan Bolts
Fig. 61 Remove Oil Pan
Fig. 62 Remove Oil Filter
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: To ease removal of the valve body, turn the
manual valve fully clockwise.
CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 63 Remove Valve Body Attaching Bolts
Fig. 64 Push Park Rod Rollers from Guide Bracket
Fig. 65 Remove Valve Body
Fig. 66 Valve Body Removed
Fig. 67 Remove Accumulators
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Dependent on engine application, some accu-
mulators will have two springs and others will have
one spring. The springs are color coded according to
application and year. When disassembling, mark accu-
mulator spring location to ease assembly.
Fig. 68 Accumulator (Underdrive)
Fig. 69 Accumulator (Overdrive)
Fig. 70 Remove Low/Reverse Accumulator Snap Ring
Fig. 71 Remove Low/Reverse Accumulator Plug
(Cover)
Fig. 72 Remove Low/Reverse Accumulator Piston
Fig. 73 Remove Low/Reverse Accumulator
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DISASSEMBLY AND ASSEMBLY (Continued)

Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
Measuring input shaft end play before disassembly
will usually indicate when a #4 thrust plate change
is required. The #4 thrust plate is located behind the
overdrive clutch hub.
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 74).
Move input shaft in and out to obtain end play
reading. End play specifications are .13 to .64 mm
(.005 to .025 inch).
Record indicator reading for reference when reas-
sembling the transaxle.
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
OIL PUMP INSPECTION
When disassembling the transaxle it is necessary
to inspect the oil pump for wear and damage.
(1) Remove the reaction shaft support bolts.
Fig. 74 Measure Input Shaft End Play
Fig. 75 Remove Pump Attaching Bolts
Fig. 76 Install Tool C-3752
Fig. 77 Remove Oil Pump
Fig. 78 Oil Pump Removed
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DISASSEMBLY AND ASSEMBLY (Continued)

(2) Remove reaction shaft support from pump
housing (Fig. 80).
(3) Remove the pump gears and check for wear
and damage.
(4) Install the gears and check clearances.
(5) Measure the clearance between the outer gear
and the pump pocket (Fig. 81). Clearance should be
0.045-0.141mm (0.0018-0.0056 in.).
(6) Measure the clearance between the outer gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 82).
(7) Measure the clearance between the inner gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 83).
Fig. 79 Remove Oil Pump Gasket
Fig. 80 Reaction Shaft Support
Fig. 81 Measure Outer Gear to Pocket
Fig. 82 Measure Outer Gear To Crescent
Fig. 83 Measure Inner Gear To Crescent
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DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: The cooler bypass valve must be
replaced if a transaxle failure has occurred. Do not
reuse old valve or attempt to clean old valve. When
installing bypass valve, insert with O-ring end
towards rear of case.
Fig. 84 Remove Bypass Valve
Fig. 85 Remove Caged Needle Bearing
Fig. 86 Remove Input Clutches Assembly
Fig. 87 No. 4 Thrust Plate
Fig. 88 Remove Front Sun Gear Assembly
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.
Fig. 89 Remove Front Carrier and Rear Annulus
Assembly
Fig. 90 Remove Rear Sun Gear
Fig. 91 Remove 2/4 Clutch Retainer Snap Ring
Fig. 92 Remove 2/4 Clutch Retainer
Fig. 93 2/4 Clutch Retainer
Fig. 94 Remove 2/4 Clutch Return Spring
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Tag 2/4 clutch pack for reassembly identifi-
cation.
Fig. 95 Remove 2/4 Clutch Pack
Fig. 96 Remove Tapered Snap Ring
Fig. 97 Remove Low/Reverse Reaction Plate
Fig. 98 Remove One Disc
Fig. 99 Remove Low/Reverse Reaction Plate Snap
Ring
Fig. 100 Remove Low/Reverse Clutch Pack
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DISASSEMBLY AND ASSEMBLY (Continued)