1996 CHRYSLER VOYAGER Service Manual

A±598 MANUAL TRANSAXLE
CONTENTS
page page
GENERAL INFORMATION
A-598 MANUAL TRANSAXLE............... 2
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES............................ 2
GEAR RATIOS........................... 3
GEAR RATIOSÐRHD VEHICLES............ 3
GEARSHIFT PATTERN..................... 3
GEARSHIFT PATTERNÐRHD VEHICLES...... 3
SELECTION OF LUBRICANT................ 2
SELECTION OF LUBRICANTÐRHD VEHICLES . 2
SPECIAL ADDITIVES..................... 2
SPECIAL ADDITIVESÐRHD VEHICLES....... 3
TRANSAXLE IDENTIFICATION INFORMATION . . 2
TRANSAXLE IDENTIFICATION
INFORMATIONÐRHD VEHICLES.......... 2
DESCRIPTION AND OPERATION
AXLE SEALS............................ 3
GEARSHIFT LEVERS...................... 3
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS..................... 4
COMMON PROBLEM CAUSES.............. 3
HARD SHIFTING......................... 4
LOW LUBRICANT LEVEL.................. 4
NOISY OPERATION....................... 4
SLIPS OUT OF GEAR..................... 4
SERVICE PROCEDURES
FLUID DRAIN AND FILL................... 4
FLUID DRAIN AND FILLÐRHD VEHICLES.... 4
REMOVAL AND INSTALLATION
A-558 TRANSAXLE ASSEMBLYÐRHD
VEHICLES........................... 16
AXLE SEALS........................... 11
BACK-UP LAMP SWITCH.................. 9
CRANKSHAFT POSITION SENSOR Ð
2.5L VM DIESEL...................... 10
CROSSOVER LEVER..................... 11
GEARSHIFT BOOT....................... 5GEARSHIFT BOOT....................... 5
GEARSHIFT CABLES...................... 5
GEARSHIFT CABLESÐRHD VEHICLES....... 7
GEARSHIFT KNOB....................... 5
GEARSHIFT MECHANISM REPLACEMENT..... 7
GEARSHIFT MECHANISM REPLACEMENTÐ
RHD VEHICLES........................ 8
INPUT SHAFT FRONT BEARING RETAINER . . . 15
INPUT SHAFT SEAL..................... 16
SELECTOR LEVER...................... 11
SHIFT SHAFT SEALS.................... 12
TRANSAXLE........................... 12
VEHICLE SPEED SENSOR DRIVE GEAR...... 9
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL......................... 39
INPUT SHAFT.......................... 32
INTERMEDIATE SHAFT................... 33
SHIFT COVER.......................... 45
SYNCHRONIZER........................ 43
TRANSAXLE........................... 20
TRANSAXLE CASE...................... 48
CLEANING AND INSPECTION
SYNCHRONIZER........................ 52
TRANSAXLE........................... 52
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE....... 56
GEARSHIFT CROSSOVER CABLE........... 52
GEARSHIFT CROSSOVER CABLE........... 55
INTERMEDIATE SHAFT BEARING PRELOAD . . 57
SPECIFICATIONS
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES........................... 59
A-598 (T-750) MANUAL TRANSAXLE....... 59
SPECIAL TOOLS
A-558 MANUAL TRANSAXLEÐRHD
VEHICLES........................... 60
A-598 (T-750) MANUAL TRANSAXLE....... 60
NS/GSA±598 MANUAL TRANSAXLE 21 - 1

GENERAL INFORMATION
A-598 MANUAL TRANSAXLE
Safety goggles should be worn at all times
when working on these transaxles.The A-598
manual transaxle uses SAE 5W-30 engine oil, meet-
ing SG and/or SG-CD qualifications, as the factory
fill lubricant. SAE G5 10W-40 engine oil is a suitable
service fill alternative.
This transaxle combines gear reduction, ratio selec-
tion, and differential functions in one unit. It is
housed in a die-cast aluminum case.
A-558 MANUAL TRANSAXLEÐRHD VEHICLES
Safety goggles should be worn at all times
when working on these transaxles.The A-558
manual transaxle uses SAE 5W-30 engine oil, meet-
ing SG and/or SG-CD qualifications, as the factory
fill lubricant. SAE G5 10W-40 engine oil is a suitable
service fill alternative.
This transaxle combines gear reduction, ratio selec-
tion, and differential functions in one unit. It is
housed in a die-cast aluminum case.
TRANSAXLE IDENTIFICATION INFORMATION
The A-598 transaxle model, assembly number,
build date, and final-drive ratio are stamped on a tag
that is attached to the top of the transaxle (Fig. 1).
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top
of the clutch housing area.
TRANSAXLE IDENTIFICATION INFORMATIONÐRHD
VEHICLES
The A-558 transaxle model, assembly number,
build date, and final-drive ratio are stamped on a tag
that is attached to the top of the transaxle (Fig. 2).NOTE: Certain transaxle assemblies utilize high-
strength steel in various gears. It is imperative that
the correct transaxle assembly number is utilized
when ordering service parts. Do not remove this
tag, so the information is available for future ser-
vice.
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top
of the clutch housing area.
SELECTION OF LUBRICANT
The A-598 manual transaxle uses SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications,
as the factory fill lubricant. G5 SAE 10W-40 engine
oil is a suitable service fill alternative.Hypoid gear
lube, manual transmission fluid, and/or auto-
matic transmission fluid should not be used in
this transaxle.Hard shifting effort, bearing, gear,
and/or synchronizer failure may occur if incorrect
fluid is used.
SELECTION OF LUBRICANTÐRHD VEHICLES
The A-558 manual transaxle uses SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications,
as the factory fill lubricant. G5 SAE 10W-40 engine
oil is a suitable service fill alternative.Hypoid gear
lube, manual transmission fluid, and/or auto-
matic transmission fluid should not be used in
this transaxle.Hard shifting effort, bearing, gear,
and/or synchronizer failure may occur if incorrect
fluid is used.
SPECIAL ADDITIVES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
Fig. 1 Transaxle Identification
Fig. 2 Transaxle Identification
21 - 2 A±598 MANUAL TRANSAXLENS/GS

sealers should be avoided, since they may adversely
affect seals.
SPECIAL ADDITIVESÐRHD VEHICLES
The addition of any fluids to the transaxle, other
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
aid in detecting fluid leaks. The use of transmission
sealers should be avoided, since they may adversely
affect seals.
GEAR RATIOS
Gear ratios for the 2.4L gasoline engine and 2.5L
Turbo Diesel MTX are as follows:
²1stÐ3.36
²2ndÐ1.90
²3rdÐ1.28
²4thÐ0.92
²5thÐ0.71
²ReverseÐ3.17
Final drive ratio of 3.88 was selected for maximum
performance. All forward gears are synchronized.
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEAR RATIOSÐRHD VEHICLES
Gear ratios for the 2.0L GAS MTX are as follows:
²1stÐ3.69
²2ndÐ2.24
²3rdÐ1.45
²4thÐ0.1.03
²5thÐ0.81
²ReverseÐ3.17
Final drive ratio of 4.08 was selected for maximum
performance. All forward gears are synchronized.
GEARSHIFT PATTERN
The A-598 transaxle shift pattern is a H±pattern
(Fig. 3). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
GEARSHIFT PATTERNÐRHD VEHICLES
The A-558 transaxle shift pattern is a H±pattern
(Fig. 4). Overdrive fifth and reverse gears are in±line
and to the right of the first through fourth gear posi-
tions.
DESCRIPTION AND OPERATION
GEARSHIFT LEVERS
The gear shift levers at the transaxle are service-
able in the vehicle. The shift levers are different from
each other and do not interchange. The select lever is
not interchangeable with model years earlier than 96
(length is different).
AXLE SEALS
The axle shaft seals are identical for both sides of
the differential and will interchange.
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
Fig. 3 A-598 Shift Pattern
Fig. 4 A-558 Shift Pattern
NS/GSA±598 MANUAL TRANSAXLE 21 - 3
GENERAL INFORMATION (Continued)