1996 CHRYSLER VOYAGER Service Manual

Fig. 159 Differential Bearing Retainer
Fig. 160 Install Oil Baffle
Fig. 161 Insert (Select) Shim and Differential
Bearing Retainer Cup
Fig. 162 Remove Extension Bearing Cup
Fig. 163 Extension
Fig. 164 Install Extension Oil Baffle
NS/GSA±598 MANUAL TRANSAXLE 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)

RING GEAR
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 94 N´m (70 ft. lbs.) torque.
DIFFERENTIAL GEARS
REMOVAL
(1) Remove pinion shaft retaining pin (Fig. 167)
(Fig. 168).
(2) Remove pinion shaft (Fig. 169).
(3) Rotate side gears to opening in differential
(Fig. 170).
(4) Remove differential gears (Fig. 171).
Fig. 165 Install Extension Bearing Cup
Fig. 166 Remove or Install Ring Gear Bolts and
Ring Gear
Fig. 167 Remove Pinion Shaft Retaining Pin
Fig. 168 Retaining Pin Removed
Fig. 169 Pinion Shaft Removal
21 - 42 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 172).
(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 173).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise. Set up dial indicator
as shown and record end play (Fig. 174) (Fig. 175).
Rotate side gear 90 degrees and record another end
play. Again, rotate side gear 90 degrees and record a
final end play.(5) Using the smallest end play recorded, shim
that side gear to within .02540 mm to .3302 mm
(0.001 to 0.013 inch). The other side gear should be
checked using the same procedure.
CAUTION: Side gear end play must be within 02540
mm to .3302 mm (0.001 to 0.013 inch). Five select
thrust washers are available: 0.027, 0.032, 0.037,
0.042, and 0.047 inch.
SYNCHRONIZER
The 1±2 synchronizer is a dual-cone synchronizer
(Fig. 176). The disassembly and assembly procedures
are the same as the 3±4 synchronizer (Fig. 177)
Fig. 171 Differential Gears
Fig. 170 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in CaseFig. 172 Install Retaining Pin
NS/GSA±598 MANUAL TRANSAXLE 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)

except you must first remove two inner and outer
cones from the synchronizer and stop ring assembly.
DISASSEMBLY
(1) Place the synchronizer on a clean shop rag on a
table.
(2) Remove the inner cones (dual-cone synchro-
nizer) from the outer cones.
(3) Remove the outer cones (dual-cone synchro-
nizer) from the synchronizer stop rings.
(4) Remove the synchronizer stop rings.
(5) Remove the synchronizer springs on both sides
of the hub.
(6) Carefully remove the synchro hub from the
synchro sleeve.
(7) Remove the three struts from the hub.
ASSEMBLY
(1) Insert the three struts into the synchro hub.
(2) Place the hub into the synchro sleeve.
NOTE: Stagger both synchronizer springs (install
tang in different winged struts).
Fig. 173 Staking Retaining Pin
Fig. 174 Checking Side Gear End Play (Typical)
Fig. 175 Checking Side Gear End Play (Typical)
Fig. 176 1±2 Synchronizer
Fig. 177 3±4 Synchronizer
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DISASSEMBLY AND ASSEMBLY (Continued)

(3) Install the synchro springs into the synchro
struts.
(4) Line up stop ring tang over the struts in the
hub. Install stop rings. Center the struts by pushing
on both stop rings.
(5) Install the outer cones (dual-cone synchronizer)
into the synchronizer stop rings.
(6) Install the inner cones (dual-cone synchronizer)
into the outer cones.
SHIFT COVER
The gearshift cover can be disassembled and worn
parts can be replaced individually (Fig. 178).
DISASSEMBLY
(1) Remove gearshift housing roll pin at shift lever
(Fig. 179).
(2) Remove shift selector shaft dust boot (Fig. 180).
(3) Remove selector shaft oil seal (Fig. 181).
(4) Remove shifter housing vent cap at crossover
lever (Fig. 182).(5) Remove roll pin and crossover lever at cross-
over shaft (Fig. 183).
(6) Remove the 5th/reverse gear blocker (Fig. 184).
(7) Remove the crossover shaft (Fig. 185).
Fig. 178 Gearshift Housing-Exploded View
Fig. 179 Shift Lever Roll Pin
NS/GSA±598 MANUAL TRANSAXLE 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)

(8) Remove selector shaft inner C-clip (Fig. 186).
(9) Remove selector shaft outer C-clip (Fig. 187).
Fig. 180 Dust Boot
Fig. 181 Oil Seal
Fig. 182 Vent Cap
Fig. 183 Crossover Lever and Roll Pin
Fig. 184 5th/Reverse Blocker
Fig. 185 Crossover Shaft
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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Drive roll pin out far enough to clear the
selector shaft, but not through. The pin must
remain in the selector so not to break the housing.
(10) Remove selector shaft center roll pin (Fig.
188).
(11) Remove selector shaft from the shift housing
(Fig. 189) (Fig. 190).
ASSEMBLY
(1) Install selector shaft components and selector
shaft into shift housing.
(2) Install selector shaft roll pin flush with selec-
tor.
(3) Install outer selector shaft C-clip.
(4) Install inner selector shaft C-clip.
(5) Install crossover shaft.
NOTE: Proper torque of the 5-R blocker bolts is
very important.
(6) Install the 5th/reverse gear blocker bolts (Fig.
191).(7) Install roll pin and crossover lever at crossover
shaft
(8) Install vent cap.
Fig. 186 Inner C-clip
Fig. 187 Outer C-clip
Fig. 188 Center Roll Pin
Fig. 189 Selector Shaft Removal
Fig. 190 Selector Shaft Components
NS/GSA±598 MANUAL TRANSAXLE 21 - 47
DISASSEMBLY AND ASSEMBLY (Continued)