1996 CHRYSLER VOYAGER Service Manual

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.
HALF SHAFT INNER SEAL
The power transfer unit half shaft inner seal is the
smaller of the two seals located on the inside of the
end cover.
REMOVAL
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 41).
(3) Tap on end cover ears to separate cover from
case (Fig. 42).
(4) Drive seal out with a hammer and small chisel
(Fig. 43).
Fig. 36 Seal Removal
Fig. 37 Seal Installation
Fig. 38 Bearing Shim and Race
Fig. 39 Installing Bearing Race
Fig. 40 Bolt Tightening Sequence
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REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Clean and inspect seal area.
(2) Install seal with a 1 1/16 inch socket (Fig. 44).
The seal must be installed with the spring side of the
seal facing end cover ball bearing. The seal will bot-
tom against a machined shoulder in the cover.
(3) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of MopartGasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.(4) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
Fig. 41 End Cover Bolts
Fig. 42 End Cover Removal
Fig. 43 Seal Removal
Fig. 44 Seal Installation
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REMOVAL AND INSTALLATION (Continued)

sequence shown in (Fig. 45). Retighten first bolt after
all other bolts are tight.
(5) Reinstall P.T.U. assembly.
(6) Check and fill fluids as required.
INPUT SHAFT END SEAL
The input shaft end seal is located on the end of
the input shaft.
REMOVAL
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 46).
(3) Tap on end cover ears to separate end cover
from case (Fig. 47).
(4) Pry out seal with a pry bar (Fig. 48).
INSTALLATION
(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into
input shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of MopartGasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 49). 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. assembly.
(7) Check and fill fluids as required.
OUTER HALF SHAFT SEAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
Fig. 45 Bolt Tightening Sequence
Fig. 46 End Cover Bolts
Fig. 47 Side Cover Removal
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REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Lift vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove seal with a chisel and hammer (Fig.
50).
INSTALLATION
(1) Clean and inspect seal area.
(2) Install new seal with seal installer MD998334
(Fig. 51).
(3) Reinstall right front half shaft.
(4) Check and fill fluids as required.
END COVER BALL BEARING
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove output seal with a hammer and chisel
(Fig. 52).
(4) Remove bearing retaining snap ring (Fig. 53).
(5) Use bearing puller MD998346 to remove bear-
ing (Fig. 54).
Fig. 48 Seal Removal
Fig. 49 Bolt Tightening Sequence
Fig. 50 Seal Removal
Fig. 51 Seal Installation
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REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Use bearing driver L-4530 and handle C-4171-2
to install bearing (Fig. 55).
(2) Install bearing retaining snap ring.
CAUTION: When installing bearing retaining snap
ring, be sure to index the snap ring so that the
snap ring does not cover bearing oil passage.
(3) Install new outer half shaft seal using
MD998334 seal installer (Fig. 56).Do not reuse the
old seal.
(4) Reinstall right front half shaft.
(5) Check and fill fluids as required.
Fig. 52 Output Seal Removal
Fig. 53 Bearing Snap Ring
Fig. 54 Bearing Removal
Fig. 55 Bearing Installation
Fig. 56 Installing New Seal
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REMOVAL AND INSTALLATION (Continued)

ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
This procedure is used when the output flange is
replaced. Replacement of the output flange requires
installation of the correct size shim to maintain bear-
ing preload.The shim must protrude from the
new output flange the same distance that the
original shim protruded from the original
flange.
(1) Stand the original output flange on end with
shim side pointing up.
(2) Place original shim into groove in top of flange.
(3) Place a straight edge across the shim.
(4) Using feeler gauge, measure the distance
between the straight edge and the top of the flange
(Fig. 57). Record this measurement.
(5) Repeat steps Step 1 through Step 4 using the
new flange and the original shim.Record this
measurement.
(6) If measurements are not equal, use a new shim
that protrudes from new output flange. Make sure it
protrudes the same amount.
(7) For Example: The original shim protrudes
0.075 inch from the original output flange. Place the
original shiminto the new output flange. The pro-
trusion of the shim in the new flange is 0.085 inch.
This indicates that a 0.010 inch thinner shim is
required to maintain the original protrusion.
(8) Install output flange and torque flange nut to
244 N´m (180 ft. lbs.).
(9) Check the turning torque of the pinion before
installing the rear cover into the P.T.U. The turning
torque should be between 2.0 N´m and 2.5 N´m (17
in. lbs. and 22 in. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
End Cover.................28N´m(250 in. lbs.)
Fill Plug...................27N´m(240 in. lbs.)
Flange Nut................162 N´m (120 ft. lbs.)
Inspection Plug.............20N´m(180 in. lbs.)
Rear Cover.................28N´m(250 in. lbs.)
Ring Gear...................94N´m(70ft.lbs.)
Fig. 57 Output Flange Shim Measurement
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