1996 CHRYSLER VOYAGER lock

(24) Remove bearing support plate (Fig. 96) (Fig.
97).
(25) Remove reverse idler gear (Fig. 98) (Fig. 99).
(26) Remove 5th gear shift rail C-clip (Fig. 100).CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when removing shift rail.
Fig. 93 Interlock Plate
Fig. 94 Shuttles
Fig. 95 Shift Rail Identification
Fig. 96 Bearing Support Plate
Fig. 97 Support Plate Removed
Fig. 98 Reverse Idler Gear
21 - 26 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(27) Carefully remove 5th gear shift rail (Fig. 101)
(Fig. 102) (Fig. 103).
(28) Remove reverse shift rail (Fig. 104) (Fig. 105).(29) Move the 1±2 and 3±4 shift rail lugs out of
the way (Fig. 106).
(30) Remove geartrain set (Fig. 107).
Fig. 99 Reverse Idler Removed
Fig. 100 Shift Rail C-clip
Fig. 101 5th Gear Shift Rail
Fig. 102 5th Gear Shift Rail Removed
Fig. 103 5th Gear Shift Rail, Interlock, and Pin
Fig. 104 Reverse Shift Rail
NS/GSA±598 MANUAL TRANSAXLE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The input shaft is serviced as an assembly.
The only serviceable components of the input shaft
are the bearings.To disassemble the intermediate shaft, differential,
synchronizers, or transaxle case, refer to the appro-
priate procedure in this section (Fig. 108).
ASSEMBLY
If the transaxle housing, intermediate shaft, bear-
ing plate, or bearings were replaced, you must adjust
the intermediate shaft bearing preload. To adjust
intermediate shaft preload, refer to Intermediate
Shaft Preload Adjustment.
(1) Install geartrain set.
CAUTION: The 5th gear shift rail has a small inter-
lock pin that is contained within the shift lug and
rail. Use caution when installing shift rail.
(2) Carefully install 5th gear shift rail (Fig. 109)
(Fig. 110).
(3) Install 5th gear shift rail C-clip.
(4) Install reverse shift rail.
(5) Install reverse idler gear (Fig. 111).
Fig. 105 Reverse Shift Rail Removed
Fig. 106 Reposition Shift Rail Lugs
Fig. 107 Geartrain Removal
Fig. 108 Geartrain Components
Fig. 109 5th Gear Shift Rail and Interlock
21 - 28 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Verify that the rear oil trough is properly
installed and retained in the bearing support plate
before installing support plate.
(6) Apply a bead of MopartGasket Maker or
equivalent onto bearing support plate. Install bearing
support plate (Fig. 112).
(7) Install interlock plate (Fig. 113) and shuttles
(Fig. 114).
(8) Install input shaft bearing snap ring (Fig. 115).
(9) Install preload shim at intermediate shaft (Fig.
116).
(10) Install bearing retainer plate. Tighten bearing
retainer plate to 17 N´m (250 in. lbs.).
NOTE: If the transaxle housing, intermediate shaft,
bearing retainer plate, or bearings are replaced, you
must perform the intermediate shaft bearing pre-
load procedure. Refer to Intermediate Shaft Bearing
Preload Adjustment procedure in the ADJUST-
MENTS section.(11) Install 5th gear.
(12) Use Special Tool 6252 to hold 5th gear and
install 5th gear nut at input shaft. Tighten the
retaining nut to 176 N´m (130 ft. lbs.).
Fig. 110 5th Gear Shift Rail
Fig. 111 Reverse Idler Gear
Fig. 112 Support Plate
Fig. 113 Interlock Plate
Fig. 114 Shuttles
NS/GSA±598 MANUAL TRANSAXLE 21 - 29
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)

(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
21 - 46 A±598 MANUAL TRANSAXLENS/GS
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)