1996 CHRYSLER VOYAGER check oil

(2) Remove reaction shaft support from pump
housing (Fig. 80).
(3) Remove the pump gears and check for wear
and damage.
(4) Install the gears and check clearances.
(5) Measure the clearance between the outer gear
and the pump pocket (Fig. 81). Clearance should be
0.045-0.141mm (0.0018-0.0056 in.).
(6) Measure the clearance between the outer gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 82).
(7) Measure the clearance between the inner gear
and the pump crescent. Clearance should be 0.020-
0.046mm (0.0008-0.0018 in.) (Fig. 83).
Fig. 79 Remove Oil Pump Gasket
Fig. 80 Reaction Shaft Support
Fig. 81 Measure Outer Gear to Pocket
Fig. 82 Measure Outer Gear To Crescent
Fig. 83 Measure Inner Gear To Crescent
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 99
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that Miller Tool 5058 is centered prop-
erly to the 2/4 clutch retainer before depressing the
tool.Press down clutch pack with finger and zero dial
indicator.The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch).If not within specifica-
tions, the clutch is not assembled properly.There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE
THICKNESSÐINPUT SHAFT END PLAY
To determine the proper thickness of the No. 4
thrust plate, select the thinnest No. 4 thrust plate.
Using petrolatum (Fig. 263) to hold thrust plate in
position, install input clutch assembly. Be sure the
input clutch assembly is completely seated (Fig. 264).
CAUTION: If view through input speed sensor hole
is not as shown above, the input clutches assembly
is not seated properly.
Remove the oil pump O-ring (Fig. 265). You will be
able to install and remove the oil pump and gasket
very easily to select the proper No. 4 thrust plate.
Fig. 257 Install 2/4 Clutch Retainer
Fig. 258 Install 2/4 Clutch Retainer Snap Ring
Fig. 259 Check 2/4 Clutch Clearance
Fig. 260 Install Rear Sun Gear
Fig. 261 Install Front Carrier and Rear Annulus
Assembly
21 - 134 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(2) Using Miller Special Tool 5052 and C-4171,
install differential bearing to differential (bearing
retainer side).
(3) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 297).
(4) Using Miller Special Tool L±4520 and C-4171,
install differential bearing to extension housing.
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 298).
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 299).The turning torque should be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
NOTE: If the turning torque was too high when
measured, install a .05 mm (.002 inch) thinner shim.
If the turning torque is was too low, install a .05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained.
Oil Baffle is not required to be installed when
making shim selection.
(e) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(f) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
Fig. 297 Differential Bearing Retainer
Fig. 298 Tool L-4436 and Torque Wrench
Fig. 299 Checking Differential Bearings Turning
Torque
21 - 142 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 299).The turning torque should be
between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A.
(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer
using Miller Special Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) Install the bearing retainer into the case.
Torque bolts to 28 N´m (250 in. lbs.).(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.
(6) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(7) Attach a dial indicator to the case and zero the
dial. Place the tip on the end of Special Tool
L-4436-A.
(8) Place a large screwdriver to each side of the
ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case
and/or differential retainer sealing surface.
(9) Using the end play measurement that was
determined, add .18mm (.007 inch). This should give
you between 5 and 18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS
MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 143
DISASSEMBLY AND ASSEMBLY (Continued)

(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with MopartSilicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 299). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a .05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a .05mm (.002 inch) thinner shim. Repeat
until 5-18 inch-pounds of turning torque is
obtained.
CLEANING AND INSPECTION
CLEANING VALVE BODY
Prior to removing any transaxle parts, plug all
openings and clean unit, preferably by steam. Clean-
liness through entire disassembly and assembly can-
not be overemphasized. When disassembling, each
part should be washed in a suitable solvent, then
dried by compressed air.Do not wipe parts with
shop towels.All mating surfaces in the transaxles
are accurately machined; therefore, careful handling
of all parts must be exercised to avoid nicks or burrs.
NOTE: Tag all springs, as they are removed, for
reassembly identification.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 300).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Check adjustment by using the preceding pro-
cedure.
Fig. 300 Gearshift Cable Adjustment
21 - 144 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

INSTALLATION
(1) To install, reverse removal procedure. Check
transaxle fluid and P.T.U. fluid and fill to level.
(2) Refer to the Specifications section for the
proper torque specifications.
END COVER SEAL
The Power Transfer Unit must be removed from
the vehicle to perform this operation. Refer to Power
Transfer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 12).
(2) Gently tap on end cover ears with a hammer to
separate end cover from the case (Fig. 13).
(3) Clean and inspect sealer surfaces.
(4) Apply MopartGasket Maker, Loctite Gasket
Eliminator No.518 or equivalent to sealing surfaces.
(5) Reinstall cover and tighten bolts to 28 N´m
(250 in. lbs.) in the sequence shown in (Fig. 14).
Retighten first bolt after all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. into vehicle.
(7) Check and fill fluids as required.
INPUT SHAFT SEAL
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
REMOVAL
(1) Remove P.T.U. end cover bolts (Fig. 15).(2) Gently tap on end cover ears to separate cover
from case (Fig. 16).
(3) Remove ring gear oil trough (Fig. 17).
(4) Remove input shaft and ring gear from case
(Fig. 18).
(5) Use Special Tool No. 7794-A (seal puller) to
remove seal (Fig. 19).
Fig. 12 P.T.U. End Cover Bolts
Fig. 13 End Cover Removal
Fig. 14 Bolt Tightening Sequence
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 169
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 20). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.(5) Apply MopartGasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.).
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
DIFFERENTIAL CARRIER SEAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
REMOVAL
(1) Remove P.T.U. from vehicle.
Fig. 15 P.T.U. End Cover Bolts
Fig. 16 End Cover Removal
Fig. 17 Oil Trough
Fig. 18 Input Shaft and Ring Gear Removal
21 - 170 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Use bearing driver L-4530 and handle C-4171-2
to install bearing (Fig. 55).
(2) Install bearing retaining snap ring.
CAUTION: When installing bearing retaining snap
ring, be sure to index the snap ring so that the
snap ring does not cover bearing oil passage.
(3) Install new outer half shaft seal using
MD998334 seal installer (Fig. 56).Do not reuse the
old seal.
(4) Reinstall right front half shaft.
(5) Check and fill fluids as required.
Fig. 52 Output Seal Removal
Fig. 53 Bearing Snap Ring
Fig. 54 Bearing Removal
Fig. 55 Bearing Installation
Fig. 56 Installing New Seal
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 179
REMOVAL AND INSTALLATION (Continued)