1996 CHRYSLER VOYAGER Service Manual

been replaced, you must perform the differential
bearing preload shim adjustment. If the transaxle
case has been replaced, you must perform both pro-
cedures.
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Burrs or nicks on the
bearing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low±mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
their original drag torque after break in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
ings.
(5) Bearing cones must not be reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction.
INTERMEDIATE SHAFT BEARING PRELOAD
The intermediate shaft preload must be checked if
the housing, intermediate shaft, bearing plate, bear-
ings, or transaxle case are replaced.
The intermediate shaft bearing preload procedure
must be done with the transaxle out of the vehicle
and on a bench.
(1) Remove end cover (Fig. 226).
(2) Remove 5th shift fork roll pin (Fig. 227).
(3) Use Special Tool 6252 to hold 5th gear. Remove
input shaft 5th gear nut (Fig. 228).
(4) Remove 5th gear synchro snap ring (Fig. 229).
(5) Remove 5th gear synchro, synchro plate, and
fork.
(6) Remove 5th drive gear off of the input shaft
(Fig. 230).
(7) Remove bearing retainer plate (Fig. 231).
(8) Remove bearing preload shim (Fig. 232).
(9) Bolt down the bearing support plate in two
places (verify dowels are in place).
(10) Seat the intermediate bearing cup against the
bearing.
(11) Measure depth of intermediate bearing cup
with dial depth gauge (Fig. 233).
Fig. 224 Crossover Cable Adjustment
Fig. 225 Auxiliary Vent Installation
Fig. 226 End Cover Removed
NS/GSA±598 MANUAL TRANSAXLE 21 - 57
ADJUSTMENTS (Continued)

(12) Add .007 (0.178) to the depth measurement
taken. This amount is the actual size of the bearing
shim needed.(13) Remove the two bolts retaining the bearing
support plate. Remove the bearing support plate.
Fig. 227 5th Gear Shift Fork Roll Pin
Fig. 228 5th Gear Retaining Nut
Fig. 229 5th Gear Synchronizer Snap Ring
Fig. 230 5th Gear
Fig. 231 Bearing Retainer Plate
Fig. 232 Bearing Preload Shim
21 - 58 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (Continued)

(14) Apply a bead of MopartGasket Maker or
equivalent onto bearing support plate. Install bearing
support plate.
(15) Install necessary shim calculated from Step
12
(16) Install bearing retainer plate. Tighten bearing
retainer plate to 17 N´m (250 in. lbs.).
(17) Install 5th drive gear onto the input shaft.
(18) Install 5th gear, synchro, fork, and plate.
(19) Install 5th gear synchro snap ring.
(20) Install 5th gear shift fork roll pin.
(21) Use Special Tool 6252 to hold 5th gear and
install new 5th gear nut at input shaft. Tighten the
retaining nut to 176 N´m (130 ft. lbs.).
(22) Use Special Tool 6930 to stake the 5th gear
retaining nut onto the input shaft (Fig. 234).
(23) 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.).
SPECIFICATIONS
A-598 (T-750) MANUAL TRANSAXLE
DESCRIPTION TORQUE
Back-up Lamp Switch..........27N´m(20ft.lbs.)
Bearing Retainer Plate........28N´m(250 in. lbs.)
Crossover Cable Adj. Screw......8N´m(70in.lbs.)
Drain Plug..................23N´m(17ft.lbs.)
Differential Housing...........54N´m(40ft.lbs.)
Diff. Bearing Retainer.........61N´m(45ft.lbs.)
Diff. Ring Gear Bolts..........94N´m(70ft.lbs.)
End Cover Bolts..............28N´m(21ft.lbs.)
Extension Housing...........28N´m(250 in. lbs.)
Gearshift Housing...........28N´m(250 in. lbs.)
*Input Gear Nut............176 N´m (130 ft. lbs.)
Input Retainer..............28N´m(250 in. lbs.)
Reverse Blocker.............12N´m(105 in. lbs.)
Transaxle Case Bolts..........29N´m(21ft.lbs.)
Vehicle Speed Sensor...........7N´m(60in.lbs.)
Vent........................6N´m(60in.lbs.)
NOTE: *The 5th/input gear is torqued to specifica-
tion and then staked in two places using Special
Tool 6930.
NOTE: Bolts that have thread sealer or torque lock
patches should not be reused. Always install new
bolts in these applications.
A-558 MANUAL TRANSAXLEÐRHD VEHICLES
DESCRIPTION TORQUE
Back-up Lamp Switch..........27N´m(20ft.lbs.)
Bearing Retainer Plate........28N´m(250 in. lbs.)
Crossover Cable Adj. Screw......8N´m(70in.lbs.)
Drain Plug..................23N´m(17ft.lbs.)
Modular Clutch to Drive
Plate Bolts................74N´m(55ft.lbs.)
Transaxle Case Bolts..........29N´m(21ft.lbs.)
Vehicle Speed Sensor...........7N´m(60in.lbs.)
Vent........................6N´m(60in.lbs.)
Fig. 233 Measure Depth Of Cup
Fig. 234 Staking 5th Gear Retaining Nut
NV T750 (A-598) MANUAL TRANSAXLE FLUID
FILL
TRANSAXLEMETRIC MEA-
SUREU.S. MEASURE
NV T750 1.9-2.2 Liters 2.0-2.3 Quarts
NS/GSA±598 MANUAL TRANSAXLE 21 - 59
ADJUSTMENTS (Continued)

SPECIAL TOOLS
A-598 (T-750) MANUAL TRANSAXLE
A-558 MANUAL TRANSAXLEÐRHD VEHICLES
A-558 MANUAL TRANSAXLE FLUID FILL
The fluid level should be within 3.175mm (1/8 inch)
from the bottom of the transaxle fill hole (vehicle must
be level when checking).
Fill transaxle to proper level with SAE 5W-30 engine oil,
meeting SG and/or SG-CD qualifications. G5 SAE
10W-40 engine oil is a suitable service fill alternative.
TRANSAXLEMETRIC MEA-
SUREU.S. MEASURE
A-558 1.9-2.2 Liters 2.0-2.3 Quarts
Bearing Splitter 1130
Slide Hammer 3752
Bearing Remover 5066
Gear Holder 6252
Bearing Remover 6786
Bearing Remover 6787
21 - 60 A±598 MANUAL TRANSAXLENS/GS

Staking Tool 6930
Bearing Installer 6933
Bearing Installer 6938
Bearing Installer 6939
Bearing Installer 6950
Puller Press C-293-PA
Adapters C-293-45
Handle C-4171
NS/GSA±598 MANUAL TRANSAXLE 21 - 61
SPECIAL TOOLS (Continued)