1996 CHRYSLER VOYAGER Service Manual

NOTE: Use screw-in dowels or phillips-head screw-
drivers to align pump to case.CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
Measure the input shaft end play with the tran-
saxle in the vertical position. This will ensure that
the measurement will be accurate.
NOTE: Input shaft end play must be .005 to .025
inch.
For example, if end play reading is .055 inch, select
No. 4 Thrust Plate which is .071 to .074 thick. This
should provide an input shaft end play reading of
.020 inch which is within specifications.
Fig. 262 Install Front Sun Gear Assembly
Fig. 263 Select Thinnest No. 4 Thrust Plate
Fig. 264 View Through Input Speed Sensor Hole
Fig. 265 Remove Oil Pump O-Ring
Fig. 266 Measure Input Shaft End Play
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 135
DISASSEMBLY AND ASSEMBLY (Continued)

See chart to select the proper No. 4 thrust plate.
Reinstall the input clutches assembly with the
selected thrust plate .
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.
NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS
4431662 .91mm (.036 in.)
4431663 1.14mm (.045 in.)
4431664 1.37mm (.054 in.)
4431665 1.60mm (.063 in.)
3836237 1.73mm (.068 in.)
4431666 1.80mm (.071 in.)
3836238 1.96mm (.077 in.)
4431667 2.03mm (.080 in.)
3836239 2.16mm (.085 in.)
4431668 2.24mm (.088 in.)
3836240 2.39mm (.094 in.)
4431669 2.46mm (.097 in.)
3836241 2.62mm (.103 in.)
4446670 2.67mm (.105 in.)
4446671 2.90mm (.114 in.)
4446672 3.15mm (.124 in.)
4446601 3.38mm (.133 in.)
Fig. 267 Install Input Clutches Assembly
Fig. 268 Install Caged Needle Bearing
Fig. 269 Install Bypass Valve
Fig. 270 Install Oil Pump Gasket
21 - 136 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Dependent on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color coded for
application and year.NOTE: To ease installation of the valve body, turn
the manual valve fully clockwise.
Fig. 271 Install Oil Pump
Fig. 272 Install Pump Attaching Bolts
Fig. 273 Install Low/Reverse Accumulator
Fig. 274 Install Low/Reverse Accumulator Plug
(Cover)
Fig. 275 Install Low/Reverse Accumulator Snap
Ring
Fig. 276 Accumulator (Underdrive)
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 137
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 277 Accumulator (Overdrive)
Fig. 278 Install Accumulators
Fig. 279 Install Valve Body
Fig. 280 Install Valve Body Attaching Bolts
Fig. 281 Install Oil Filter
Fig. 282 Install Oil Pan
21 - 138 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(1) Install transaxle solenoid pack (Fig. 284).
(2) Install input and output speed sensors.
This concludes the assembly of the transaxle cen-
terline.
DIFFERENTIAL REPAIR
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
DISASSEMBLE
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
285) (Fig. 286).
(2) Remove the differential bearing retainer and
bolts (Fig. 287) (Fig. 288).(3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the tran-
saxle.
Fig. 283 Install Pan Bolts
Fig. 284 Install Solenoid Pack
Fig. 285 Differential Cover Bolts
Fig. 286 Remove Differential Cover
Fig. 287 Differential Retainer Bolts
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 139
DISASSEMBLY AND ASSEMBLY (Continued)

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side.
(5) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the bearing retainer side (Fig. 289) (Fig.
290) (Fig. 291).
(6) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing.
(7) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 292) (Fig. 293).
Fig. 288 Remove Bearing Retainer
Fig. 289 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
Fig. 290 Position Tool 5048 Over Button and Collets
at Differential Bearing (Ring Gear Side)
Fig. 291 Remove Differential Bearing Cone (Ring
Gear Side)
Fig. 292 Position Bearing Cup Remover Tool in
Retainer
21 - 140 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

CHECKING SIDE GEAR END PLAY
Check side gear end play whenever the differential
is removed for service.
NOTE: Side gear end play must be BETWEEN 0.001
to 0.013 inch.
ASSEMBLE
NOTE: Use MoparTSilicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(1) Using Miller Special Tool L-4410, and C-4171,
install differential bearing to differential (extension
housing side) (Fig. 296).
Fig. 293 Remove Bearing Cup
DIFFERENTIAL SERVICE TOOLS
COMPONENT REMOVER INSTALLER
Diff. Bear. On
Retainer Side5048, 5048-4
Collets,
L-4539-2
Button5052, C-4171
Diff. Bear. On
Ext. Hous. Side5048, 5048-3
Collets,
L-4539-2
ButtonL-4410, C-4171
Diff. Race. On
Retainer Side6062-A 6061, C-4171
Diff. Race. On
Ext. Hous. SideL-4518 L-4520, C-4171
Extension
Housing Seal7794-A, C-637
Slide HammerL-4520, C-4171
Bearing
Retainer Seal794-A, C-637
Slide HammerL-4520, C-4171
Fig. 294 Checking Side Gear End Play (Extension
Housing Side)
Fig. 295 Checking Side Gear End Play (Bearing
Retainer Side)
Fig. 296 Position Bearing Cone Onto Differential
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 141
DISASSEMBLY AND ASSEMBLY (Continued)