1996 CHRYSLER VOYAGER Service Manual

INTERMEDIATE SHAFT
DISASSEMBLY
(1) Install intermediate shaft into shop press.
(2) Install bearing splitter 1130 under the 4th
speed gear clutch teeth (Fig. 132).
(3) Remove intermediate shaft rear bearing snap
ring (Fig. 133).
(4) Position Special Tool 6792±1 over intermediate
shaft.
CAUTION: To prevent damaging the intermediate
shaft, grasp the bottom of the shaft when doing
shop press procedures.
(5) Using Special Tool 6792±1 as a driver, press off
and remove 4th speed gear (Fig. 134).
(6) Remove intermediate shaft from shop press.
(7) Install Special Tool 6938 onto front intermedi-
ate bearing for protection.
(8) Remove 3±4 synchro snap ring (Fig. 135) (Fig.
136).NOTE: The 3±4 synchro has a master spline (Fig.
137).
Fig. 130 Position Bearing
Fig. 131 Press Input Bearing Onto Shaft
Fig. 132 Bearing Splitter Installed
Fig. 133 Intermediate Shaft Rear Bearing Snap Ring
Fig. 134 Press Off 4th Speed Gear
NS/GSA±598 MANUAL TRANSAXLE 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

(9) Remove 3±4 synchro assembly and 3rd speed
gear (Fig. 138).
(10) Remove thrust washer outer retainer (Fig.
139).
(11) Remove the two split washers.
(12) Remove the anti-spin pin (Fig. 140).
(13) Remove 2nd speed gear (Fig. 141).
(14) Remove 1±2 synchro snap ring (precision
ground) (Fig. 142) (Fig. 143).
Fig. 136 Snap Ring Removed
Fig. 135 3±4 Synchro Snap RingFig. 137 Master Spline
21 - 34 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 139 Thrust Washer Outer Retainer
Fig. 138 3±4 Synchro and 3rd Speed GearFig. 140 Anti-Spin Pin
Fig. 141 2nd Speed Gear
NS/GSA±598 MANUAL TRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

(15) Remove 1±2 dual cone synchro assembly and
1st speed gear (Fig. 144).
(16) Install Special Tool 1130 bearing splitter
under the plastic intermediate shaft front bearing
(17) Position shaft into shop press.
(18) Position Special Tool MD998802±01 over the
intermediate shaft.
(19) Remove the intermediate shaft front bearing
(Fig. 145).
Fig. 143 Snap Ring Removed
Fig. 142 1±2 Synchro Snap Ring
Fig. 144 1±2 Dual Cone Synchro
21 - 36 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY
(1) Position intermediate shaft front bearing onto
intermediate shaft. Install Special Tool 6938 over
bearing and shaft. Install the intermediate shaft
front bearing (Fig. 146).
(2) Remove intermediate shaft from shop press.
(3) Position intermediate shaft bearing side down.
Place intermediate shaft into Special Tool 6938 to
protect front bearing. Install 1±2 dual cone synchro
assembly and 1st speed gear.
(4) Install 1±2 synchro snap ring (precision
ground) (Fig. 147).
(5) Install 2nd speed gear (Fig. 148).
(6) Install the anti-spin pin (Fig. 149).
(7) Install the two split washers.
(8) Install thrust washer outer retainer (Fig. 150).
NOTE: The 3±4 synchro has a master spline (Fig.
151).
(9) Install 3±4 synchro assembly and 3rd speed
gear.(10) Install 3±4 synchro snap ring (Fig. 152).
(11) Install 4th speed gear over the 3±4 synchro.
Fig. 145 Intermediate Shaft Front Bearing
Fig. 146 Install Intermediate Shaft Front Bearing
Fig. 147 1±2 Synchro Snap Ring
NS/GSA±598 MANUAL TRANSAXLE 21 - 37
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 148 2nd Speed Gear
Fig. 151 Master SplineFig. 149 Anti-Spin Pin
Fig. 150 Thrust Washer Outer Retainer
21 - 38 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(12) Position the intermediate shaft rear bearing
onto the intermediate shaft.
(13) Install the intermediate shaft into a shop
press.
(14) Position Special Tool MD998323 over the
intermediate shaft rear bearing
(15) Press on the intermediate shaft rear bearing
(Fig. 153).
(16) Install intermediate shaft rear bearing snap
ring.
DIFFERENTIAL
NOTE: The differential is typically serviced as an
assembly. The only parts that are serviceable within
the differential are the differential bearing cups and
cones. If any other part fails within the differential,
you should replace the differential assembly.Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle gear case
²Differential case
²Differential bearings
²Differential cover
Refer toBearing Adjustment Procedurein the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.DIFFERENTIAL BEARINGS
Differential bearings are usually serviced as pairs.
If one differential bearing fails, you should replace
both bearing cups and cones
Fig. 152 3±4 Synchro Snap RingFig. 153 Intermediate Shaft Rear Bearing Installation
NS/GSA±598 MANUAL TRANSAXLE 21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)

.
Fig. 154 Remove Differential Bearing Cone
Fig. 155 Install Differential Bearing Cone
Fig. 156 Remove Differential Bearing Cone
Fig. 157 Install Differential Bearing Cone
Fig. 158 Remove Differential Bearing Retainer Cup
21 - 40 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)