1996 CHRYSLER VOYAGER lock

INSTALLATION
To install valve body, reverse removal procedure
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
NOTE: To ease installation of the valve body, turn
the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while
shifting manual lever assembly out of the installation
position.
TRANSAXLE
Transaxle removal does NOT require engine
removal.
See Group 7, Cooling to drain engine cooling sys-
tem and remove coolant return extension (3.0 liter
engine only).The transaxle and torque converter must be
removed as an assembly; otherwise, the torque con-
verter drive plate, pump bushing or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the drive plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner duct. Disconnect transaxle
shift linkage at manual valve lever (Fig. 34).
(3) Squeeze grommet clips and remove cable at
transaxle bracket (Fig. 35) (Fig. 36).
(4) Remove 16±way engine harness connector from
dipstick tube bracket. Remove dipstick tube bracket
nut at cylinder head. Remove dipstick tube.
(5) Remove transaxle cooler lines.
(6) Remove connector at transaxle solenoid pack.
(7) Remove input and output speed sensor wiring
connectors (Fig. 37) (Fig. 38).
Fig. 32 Remove Valve Body
Fig. 33 Valve Body Removed
Fig. 34 Shift Linkage At Manual Valve Lever
Fig. 35 Grommet Clips
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 89
REMOVAL AND INSTALLATION (Continued)

(18) Rotate engine clockwise to gain access to
torque converter bolts (Fig. 41). Remove torque con-
verter mounting bolts.
(19) Remove front engine mount insulator and
bracket (Fig. 42).
(20) Remove rear engine mount shield.
(21) Remove rear engine mount bracket bolts and
bracket.
(22) Remove starter bolts and set starter aside. Do
not allow the starter to hang from battery cable (Fig.
43).
(23) Position transmission jack securely under
transaxle (Fig. 44).
(24) Remove left fender splash shield.
(25) With transmission jack in position, remove
the left transmission mount.
(26) Lower transaxle to access the crankshaft posi-
tion sensor, remove crankshaft position sensor from
bell housing. For installation procedure refer to sec-
tion 8D of this service manual.CAUTION: Remove the crankshaft position sensor
from the bell housing before transmission removal
or installation.
(27) Remove lower bellhousing bolts.
(28) Carefully lower the transaxle assembly from
vehicle.
INSTALLATION
(1) For installation of transaxle, reverse the above
procedure.
(2) Check and/or adjust gearshift cable.
(3) Refill transaxle with MOPARtATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
Fig. 41 Rotate Engine
Fig. 42 Remove Front Engine Mount
Fig. 43 Starter Assembly
Fig. 44 Position Transmission Jack
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 91
REMOVAL AND INSTALLATION (Continued)

NOTE: To ease removal of the valve body, turn the
manual valve fully clockwise.
CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 63 Remove Valve Body Attaching Bolts
Fig. 64 Push Park Rod Rollers from Guide Bracket
Fig. 65 Remove Valve Body
Fig. 66 Valve Body Removed
Fig. 67 Remove Accumulators
21 - 96 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 231 Install Strap Bolts
Fig. 232 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
Fig. 233 Tighten Stirrup Strap Bolts To 23 N´m
(200 in. lbs.)
Fig. 234 Bend Tabs On Strap Up Against Flats Of
Bolts
Fig. 235 Install Transfer Shaft Bearing Cone
Fig. 236 Install Bearing Cup To Shaft
21 - 128 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Dependent on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color coded for
application and year.NOTE: To ease installation of the valve body, turn
the manual valve fully clockwise.
Fig. 271 Install Oil Pump
Fig. 272 Install Pump Attaching Bolts
Fig. 273 Install Low/Reverse Accumulator
Fig. 274 Install Low/Reverse Accumulator Plug
(Cover)
Fig. 275 Install Low/Reverse Accumulator Snap
Ring
Fig. 276 Accumulator (Underdrive)
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 137
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)

sequence shown in (Fig. 45). Retighten first bolt after
all other bolts are tight.
(5) Reinstall P.T.U. assembly.
(6) Check and fill fluids as required.
INPUT SHAFT END SEAL
The input shaft end seal is located on the end of
the input shaft.
REMOVAL
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 46).
(3) Tap on end cover ears to separate end cover
from case (Fig. 47).
(4) Pry out seal with a pry bar (Fig. 48).
INSTALLATION
(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into
input shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of MopartGasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 49). 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. assembly.
(7) Check and fill fluids as required.
OUTER HALF SHAFT SEAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
Fig. 45 Bolt Tightening Sequence
Fig. 46 End Cover Bolts
Fig. 47 Side Cover Removal
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 177
REMOVAL AND INSTALLATION (Continued)

(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)