1996 CHRYSLER VOYAGER Service Manual

FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certainseal leaks. These holes are located on the bottom side
of the assembly (Fig. 6).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 6) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
If fluid is leaking from weep hole B (Fig. 6) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input shaft end seal
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner
seal and P.T.U. input shaft cover seal should be
replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.
REMOVAL AND INSTALLATION
POWER TRANSFER UNIT (P.T.U.)
REMOVAL
(1) Raise vehicle and remove front wheels.
Fig. 3 Seal Location
Fig. 4 Seal Location
Fig. 5 Seal Location
Fig. 6 Weep Hole Locations
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 167
DIAGNOSIS AND TESTING (Continued)

CAUTION: A certain amount of oil will drain out of
the transaxle when the drive shaft is removed.
(2) Remove right front drive shaft. Install a plug
into the right driveshaft seal hole. Refer to Group 2,
Suspension to remove or install wheel hub nut and
right drive shaft.
(3) Mark propeller shaft front flange.
(4) Separate propeller shaft from P.T.U. assembly
(Fig. 7).
CAUTION: Do not let propeller shaft to hang freely.
Damage to the shaft will occur.
(5) Suspend propeller shaft from underbody of
vehicle.
(6) Remove cradle plate (Fig. 8).
(7) Remove the Power Transfer Unit mounting
bracket bolts at the rear of the unit (Fig. 9).
(8) Remove the right outboard support bracket and
bolts near the right axle shaft.(9) Remove the four mounting bolts for the P.T.U.
(Fig. 10) and (Fig. 11).
(10) Remove P.T.U. assembly from vehicle.
Fig. 7 Driveshaft Flange
Fig. 8 Cradle Plate
Fig. 9 Remove Rear P.T.U Bracket Bolts
Fig. 10 P.T.U. Lower Mounting Bolts
Fig. 11 P.T.U. Upper Mounting Bolts
21 - 168 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) To install, reverse removal procedure. Check
transaxle fluid and P.T.U. fluid and fill to level.
(2) Refer to the Specifications section for the
proper torque specifications.
END COVER SEAL
The Power Transfer Unit must be removed from
the vehicle to perform this operation. Refer to Power
Transfer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 12).
(2) Gently tap on end cover ears with a hammer to
separate end cover from the case (Fig. 13).
(3) Clean and inspect sealer surfaces.
(4) Apply MopartGasket Maker, Loctite Gasket
Eliminator No.518 or equivalent to sealing surfaces.
(5) Reinstall cover and tighten bolts to 28 N´m
(250 in. lbs.) in the sequence shown in (Fig. 14).
Retighten first bolt after all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. into vehicle.
(7) Check and fill fluids as required.
INPUT SHAFT SEAL
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
REMOVAL
(1) Remove P.T.U. end cover bolts (Fig. 15).(2) Gently tap on end cover ears to separate cover
from case (Fig. 16).
(3) Remove ring gear oil trough (Fig. 17).
(4) Remove input shaft and ring gear from case
(Fig. 18).
(5) Use Special Tool No. 7794-A (seal puller) to
remove seal (Fig. 19).
Fig. 12 P.T.U. End Cover Bolts
Fig. 13 End Cover Removal
Fig. 14 Bolt Tightening Sequence
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 169
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 20). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.(5) Apply MopartGasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.).
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
DIFFERENTIAL CARRIER SEAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
REMOVAL
(1) Remove P.T.U. from vehicle.
Fig. 15 P.T.U. End Cover Bolts
Fig. 16 End Cover Removal
Fig. 17 Oil Trough
Fig. 18 Input Shaft and Ring Gear Removal
21 - 170 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

(2) Use a pry bar to remove seal from retainer
plate (Fig. 21). Be careful not to damage seal journal
when removing seal.
INSTALLATION
(1) Using a large socket, carefully install new seal.
The spring side of the seal must face the transaxle
differential.
(2) Reinstall the P.T.U. into the vehicle.(3) Check and fill fluids as required.
REAR COVER O-RING
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear cover retaining bolts (Fig. 22).
(3) Index rear cover to the case for later reassem-
bly (Fig. 23).
(4) Pull rear cover out of the P.T.U. case (Fig. 24).
(5) Remove rear cover O-Ring (Fig. 25).
INSTALLATION
(1) To install, reverse removal procedure.
POWER TRANSFER UNIT OUTPUT SEAL
The power transfer unit must be removed from the
vehicle to replace this seal.
Fig. 19 Seal Removal
Fig. 20 Seal Installation
Fig. 21 Transaxle Differential Carrier Seal
Fig. 22 Rear Cover Bolts
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 171
REMOVAL AND INSTALLATION (Continued)