1996 CHRYSLER VOYAGER Service Manual

(22) Remove input shaft bearing snap ring (Fig.
91) (Fig. 92).
(23) Remove interlock plate (Fig. 93) and shuttles
(Fig. 94).NOTE: The shift rails are positioned as shown (Fig.
95).
Fig. 87 Bearing Retainer Plate Bolts
Fig. 88 Bearing Retainer Plate
Fig. 89 Retainer Plate Removed
Fig. 90 Bearing Preload Shim
Fig. 91 Input Shaft Bearing Snap Ring
Fig. 92 Snap Ring Removed
NS/GSA±598 MANUAL TRANSAXLE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)

(24) Remove bearing support plate (Fig. 96) (Fig.
97).
(25) Remove reverse idler gear (Fig. 98) (Fig. 99).
(26) Remove 5th gear shift rail C-clip (Fig. 100).CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when removing shift rail.
Fig. 93 Interlock Plate
Fig. 94 Shuttles
Fig. 95 Shift Rail Identification
Fig. 96 Bearing Support Plate
Fig. 97 Support Plate Removed
Fig. 98 Reverse Idler Gear
21 - 26 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(27) Carefully remove 5th gear shift rail (Fig. 101)
(Fig. 102) (Fig. 103).
(28) Remove reverse shift rail (Fig. 104) (Fig. 105).(29) Move the 1±2 and 3±4 shift rail lugs out of
the way (Fig. 106).
(30) Remove geartrain set (Fig. 107).
Fig. 99 Reverse Idler Removed
Fig. 100 Shift Rail C-clip
Fig. 101 5th Gear Shift Rail
Fig. 102 5th Gear Shift Rail Removed
Fig. 103 5th Gear Shift Rail, Interlock, and Pin
Fig. 104 Reverse Shift Rail
NS/GSA±598 MANUAL TRANSAXLE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The input shaft is serviced as an assembly.
The only serviceable components of the input shaft
are the bearings.To disassemble the intermediate shaft, differential,
synchronizers, or transaxle case, refer to the appro-
priate procedure in this section (Fig. 108).
ASSEMBLY
If the transaxle housing, intermediate shaft, bear-
ing plate, or bearings were replaced, you must adjust
the intermediate shaft bearing preload. To adjust
intermediate shaft preload, refer to Intermediate
Shaft Preload Adjustment.
(1) Install geartrain set.
CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when installing shift rail.
(2) Carefully install 5th gear shift rail (Fig. 109)
(Fig. 110).
(3) Install 5th gear shift rail C-clip.
(4) Install reverse shift rail.
(5) Install reverse idler gear (Fig. 111).
Fig. 105 Reverse Shift Rail Removed
Fig. 106 Reposition Shift Rail Lugs
Fig. 107 Geartrain Removal
Fig. 108 Geartrain Components
Fig. 109 5th Gear Shift Rail and Interlock
21 - 28 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that the rear oil trough is properly
installed and retained in the bearing support plate
before installing support plate.
(6) Apply a bead of MopartGasket Maker or
equivalent onto bearing support plate. Install bearing
support plate (Fig. 112).
(7) Install interlock plate (Fig. 113) and shuttles
(Fig. 114).
(8) Install input shaft bearing snap ring (Fig. 115).
(9) Install preload shim at intermediate shaft (Fig.
116).
(10) Install bearing retainer plate. Tighten bearing
retainer plate to 17 N´m (250 in. lbs.).
NOTE: If the transaxle housing, intermediate shaft,
bearing retainer plate, or bearings are replaced, you
must perform the intermediate shaft bearing pre-
load procedure. Refer to Intermediate Shaft Bearing
Preload Adjustment procedure in the ADJUST-
MENTS section.(11) Install 5th gear.
(12) Use Special Tool 6252 to hold 5th gear and
install 5th gear nut at input shaft. Tighten the
retaining nut to 176 N´m (130 ft. lbs.).
Fig. 110 5th Gear Shift Rail
Fig. 111 Reverse Idler Gear
Fig. 112 Support Plate
Fig. 113 Interlock Plate
Fig. 114 Shuttles
NS/GSA±598 MANUAL TRANSAXLE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)

(13) Use Special Tool 6930 to stake the 5th gear
retaining nut onto the input shaft (Fig. 117).
(14) Install 5th gear shift fork, synchro, and plate
(Fig. 118).(15) Install snap ring at 5th gear synchro (Fig.
119).
(16) Install 5th gear shift fork roll pin (Fig. 120).
Fig. 115 Input Shaft Bearing Snap Ring
Fig. 116 Bearing Preload Shim
Fig. 117 Staking 5th Gear Retaining Nut
Fig. 118 5th Gear Shift Fork, Rail, and Synchronizer
Fig. 119 5th Gear Synchronizer Snap Ring
Fig. 120 5th Gear Shift Fork Roll Pin
21 - 30 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(17) Apply a bead of MopartGasket Maker or
equivalent onto end cover. Install 5th gear/synchro
end cover. Tighten bolts to 28 N´m (250 in. lbs.).
(18) Move 3±4 shift lug into position. Install 3±4
roll pin at 3±4 shift lug (Fig. 121).
(19) Install 1±2 roll pin at 1±2 shift fork (Fig. 122).
(20) Install reverse pivot lever actuator arm (Fig.
123).
NOTE: When installing shift detents, align the
detent slots in line with the longitudinal axis of the
transaxle (same direction as the shift rails).
NOTE: On some A-598 transaxles all four detent
springs are of the same color and spring tension.
On other A-598 transaxles, three identical springs
are used on the forward gear detents, while the
reverse detent spring is a different tension and
color.(21) Install shift detents, springs, and rollers (Fig.
124) (Fig. 125).
(22) Install shift cover splash shield (Fig. 126).
Fig. 121 3±4 Shift Lug Roll Pin
Fig. 122 1±2 Shift Fork Roll Pin
Fig. 123 Reverse Pivot Lever Actuator Arm
Fig. 124 Shift Detent Rollers
Fig. 125 Shift Detent Springs
NS/GSA±598 MANUAL TRANSAXLE 21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Two of the bolts retaining the shift cover are
shouldered (Fig. 127).
(23) Apply a bead of MopartGasket Maker or
equivalent onto shift cover. Line up the shift detent
springs so the springs are aligned with the shift
cover spring pockets. Install shift cover. Tighten shift
cover bolts to 28 N´m (250 in. lbs.).
(24) Install differential assembly.
(25) Apply a bead of MopartGasket Maker or
equivalent onto differential cover. Install differential
cover. Tighten differential cover bolts to 61 N´m (45
ft. lbs.).
(26) Apply a bead of RTV silicone to the differen-
tial bearing retainer. Install differential bearing
retainer. Tighten differential bearing retainer bolts to
61 N´m (45 ft. lbs.).
(27) Apply a bead of RTV silicone to the extension
housing. Install extension housing. Tighten extension
housing bolts to 28 N´m (250 in. lbs.).
(28) Install engine mount bracket.
INPUT SHAFT
The input shaft is serviced as an assembly. The
only serviceable component of the input shaft is the
rear bearing.
DISASSEMBLY
(1) Install the bearing splitter 1130 under the rear
bearing.
(2) Position the input shaft into a shop press (Fig.
128).
(3) Remove the rear bearing (Fig. 129).
ASSEMBLY
(1) Position replacement bearing onto the input
shaft (Fig. 130).
(2) Place input shaft into shop press.
(3) Position Special Tool 6950 over input shaft on
top of bearing.
(4) Press input shaft bearing into position (Fig.
131).
Fig. 126 Shift Cover Splash Shield
Fig. 127 Gearshift Cover Shouldered Bolts
Fig. 128 Input Shaft
Fig. 129 Remove Bearing
21 - 32 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)