1996 CHRYSLER VOYAGER Service Manual

NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 147 OD/Reverse Pressure Plate
Fig. 148 Waved Snap Ring
Fig. 149 Remove OD Clutch Pack
Fig. 150 Overdrive Clutch Pack
Fig. 151 Overdrive Shaft Assembly
Fig. 152 Underdrive Shaft Assembly
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 111
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
NOTE: The OD/UD clutches reaction plate has a
step on both sides. Install the OD/UD clutches reac-
tion plate tapered step side up.
NOTE: Tag underdrive clutch pack for reassembly
identification.
Fig. 153 No. 2 Needle Bearing
Fig. 154 OD/UD Reaction Plate Tapered Snap Ring
Fig. 155 OD/UD Reaction Plate
Fig. 156 Remove One UD Clutch Disc
Fig. 157 UD Clutch Flat Snap Ring
21 - 112 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 158 Underdrive Clutch Pack
Fig. 159 UD Spring Retainer Snap Ring
Fig. 160 UD Return Spring and Retainer
Fig. 161 Underdrive Clutch Piston
Fig. 162 Input Hub Tapered Snap Ring
Fig. 163 Tap on Input Hub
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 113
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 164 Input Hub Removed
Fig. 165 Pull Retainer from Piston
Fig. 166 Remove Snap Ring
Fig. 167 Snap Ring and Return Spring
Fig. 168 Remove Input Shaft Snap Ring
Fig. 169 Remove Input Shaft
21 - 114 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
Fig. 170 Install Input Shaft
Fig. 171 Install Input Shaft Snap Ring
Fig. 172 Return Spring and Snap Ring
Fig. 173 Install Snap Ring
Fig. 174 Install OD/Reverse Piston
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 115
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The OD/UD Reaction Plate, Snap Rings, and
Input Clutches Retainer is not interchangeable with
previous year 41TE components. The snap rings
are thicker and the position of the ring lands have
changed.
Fig. 175 Install Input Shaft Hub Assembly
Fig. 176 Install Input Hub Tapered Snap Ring
Fig. 177 Underdrive Clutch Piston
Fig. 178 Seal Compressor Special Tool 5067
Fig. 179 UD Return Spring and Retainer
21 - 116 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Compress return spring just enough to
remove or install snap ring.
The OD/UD clutches reaction plate has a step on
both sides. Install the OD/UD clutches reaction plate
tapered step side up.
Fig. 180 Install UD Spring Retainer and Snap Ring
Fig. 181 Underdrive Clutch Pack
Fig. 182 UD Clutch Flat Snap Ring
Fig. 183 Install Last UD Clutch Disc
Fig. 184 OD/UD Reaction Plate
Fig. 185 Tapered Snap Ring
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 117
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Underdrive clutch pack clearance must be
0.91 to 1.47 mm (.036 to .058 inch).Select the
proper reaction plate to achieve specifications:
Fig. 186 Seating Tapered Snap Ring
Fig. 187 Set Up Dial Indicator for Clutch Clearance
Fig. 188 Use Hook Tool to Raise One Clutch Disc
UNDERDRIVE REACTION PLATE CHART
Fig. 189 Install OD Clutch Pack
21 - 118 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)