2001 CHRYSLER VOYAGER ABS

The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in series with
the power steering fluid return line, between the
steering gear and the power steering fluid reservoir.
This lowers the temperature of the power steering
fluid prior to it entering the power steering fluid res-
ervoir where it is resupplied to the power steering
pump.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle using a frame contact type hoist
or supported using jack stands. See Hoisting in
Lubrication And Maintenance.
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
16). Remove the cooler.
INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 16). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering fluid hoses on the cooler.
Be sure hose clamps are installed on hose pastthe upset bead on the power steering cooler
tubes.
(3) Lower the vehicle to a point where front tires
are just off the ground.
(4) Perform Power Steering Pump Initial Opera-
tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)
Fig. 16 POWER STEERING COOLER
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
RSPUMP19-31
FLUID COOLER (Continued)

TRANSFER SYSTEM - OUTPUT
SHAFT/GEAR/BEARING
REMOVAL
NOTE: Transfer Gear should be removed for repair
of output shaft, to obtain an accurate output shaft
turning torque measurement upon reassembly.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/TRANSFER SYSTEM - REMOVAL)
NOTE: Transaxle geartrain must be removed to gain
access to and service output shaft. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH -
DISASSEMBLY)
(1) Using a suitable punch, bend retaining strap
tabs flat to facilitate bolt removal (Fig. 238).
(2) Remove retaining strap and stirrup-to-gear
bolts (Fig. 239).
(3) Remove retaining strap (Fig. 240).
Fig. 238 Bend Strap Tabs Flat
1 - RETAINING TABS
2 - STRAP
Fig. 239 Remove Strap Bolts
1 - RETAINING BOLTS
2 - STIRRUP
3 - STRAP
Fig. 240 Remove Strap From Stirrup and Gear
1 - OUTPUT GEAR
2 - STRAP
21 - 126 AUTOMATIC - 31THRS

(7) Install output shaft gear onto shaft. Use Tool
L-4439 to get gear started (Fig. 258).
(8) Install Tool L-4434 and C-4658. Install washer
and nut (Fig. 259).
(9) Torque output shaft retaining nut to 271 N´m
(200 ft. lbs.) (Fig. 260).
(10) Set up Tool L-4432 and C-4658 as shown in
(Fig. 261). Install dial indicator and measure output
shaft end play.
(11) Using an in. lb. torque wrench, measure out-
put shaft bearing turning torque (Fig. 262).
(12) Install stirrup and strap. Install bolts but do
not tighten.
NOTE: Once the stirrup assembly is positioned
onto the output gear, it is necessary to ªclockº the
stirrup against the flats of the output gear retaining
nut.(13) Rotate stirrup clockwise against flats of gear
retaining nut (Fig. 263).
(14) Torque stirrup and strap bolts to 23 N´m (200
in. lbs..) (Fig. 264).
(15) Bend tabs of strap up against ªflatsºof retain-
ing bolts to prevent bolts from backing out of gear in
the event they come loose.
(16) Install transfer shaft and gear. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/TRANSFER SYSTEM - INSTALLATION)
(17) Assemble transaxle geartrain. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 31TH
- ASSEMBLY)
Fig. 257 Output Shaft and (Select) Shims in Position
1 - BEARING CUP
2 - (SELECT) SHIM
3 - OUTPUT SHAFT ASSEMBLY
Fig. 258 Start Output Shaft Gear onto Output Shaft
1 - OUTPUT SHAFT GEAR
2 - OUTPUT SHAFT
3 - SPECIAL TOOL L-4439
Fig. 259 Holding Output Shaft Gear
1 - OUTPUT SHAFT
2 - SCREW (2)
3 - SPECIAL TOOL L-4434 AND C-4658
4 - WASHER
5 - NUT
Fig. 260 Tighten Output Shaft Retaining Nut
1 - OUTPUT SHAFT GEAR
2 - SPECIAL TOOL L-4434 AND C-4658
3 - SCREW (2)
RSAUTOMATIC - 31TH21 - 131
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

TRANSFER SYSTEM -
TRANSFER SHAFT/GEAR/
BEARING
REMOVAL
(1) Remove transfer gear cover bolts (Fig. 265).
(2) Separate transfer gear cover from transaxle
(Fig. 266). Repair any cover imperfections. Clean
cover and case of old adhesive sealant.(3) Using a suitable punch, bend retaining strap
tabs to facilitate bolt removal.
(4) Remove stirrup and retaining strap-to-transfer
gear bolts.
(5) Remove stirrup and retaining strap.
(6) Using Tool L-4434 (Fig. 267), remove transfer
shaft gear retaining nut and washer (Fig. 268).
Fig. 265 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
Fig. 266 Remove Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 267 Remove Transfer Shaft Gear Retaining Nut
1 - TRANSFER SHAFT GEAR
2 - SCREW (2)
3 - OUTPUT SHAFT GEAR
4 - SPECIAL TOOL L-4434
Fig. 268 Transfer Shaft Gear Nut and Washer
1 - OUTPUT SHAFT GEAR
2 - TRANSFER SHAFT GEAR
3 - WASHER
4 - NUT
21 - 134 AUTOMATIC - 31THRS

(14) Using Tool L-4434 and adapter C-4658 (Fig.
293), torque transfer shaft gear retaining nut to 271
N´m (200 ft. lbs.).
(15) Measure transfer shaft end play. Set up Tool
L-4432 and C-4658 as shown in (Fig. 294). Measure
end play with dial indicator.
(16) Position stirrup and strap on transfer gear.
(17) Install bolts but do not tighten.
(18) Rotate stirrup clockwise until it contacts
transfer gear retaining nut flat.(19) Torque stirrup and strap-to-transfer gear bolts
to 23 N´m (200 in. lbs.).
(20) Bend tabs of strap up against ªflatsº of retain-
ing bolts.
(21) Install a bead of Moparž Silicone Rubber
Adhesive Sealant to transfer gear cover (Fig. 295).
Immediately install to transaxle case.
(22) Install and torque transfer gear cover-to-case
bolts (Fig. 296) to 19 N´m (165 in. lbs.) .
Fig. 293 Tighten Transfer Shaft Gear Retaining Nut
to 271 N´m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - TORQUE WRENCH
3 - SPECIAL TOOL L-4434 AND ADAPTER C-4658
Fig. 294 Measuring Transfer Shaft End-Play
1 - SPECIAL TOOL L-4432 AND C-4658
2 - TRANSFER SHAFT GEAR
3 - STEEL BALL (USE GREASE TO HOLD IN PLACE)
4 - DIAL INDICATOR
5 - SCREW (2)
Fig. 295 Install Rear Cover
1 - OUTPUT SHAFT GEAR
2 - USE MOPAR SILICONE RUBBER ADHESIVE SEALER
3 - REAR COVER
4 - TRANSFER SHAFT GEAR
Fig. 296 Rear Cover Bolts
1 - REAR COVER
2 - REAR COVER BOLTS (10)
RSAUTOMATIC - 31TH21 - 141
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(20) Remove cooler bypass valve (Fig. 37).
(21) Remove #1 needle bearing (Fig. 38).(22) Remove input clutch assembly (Fig. 39).
(23) Remove #4 thrust plate (Fig. 40).
Fig. 37 Remove Bypass Valve
1 - COOLER BYPASS VALVE
Fig. 38 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 39 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 40 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
21 - 174 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

(24) Remove front sun gear assembly and #4
thrust washer (Fig. 41).
(25) Remove front carrier and rear annulus assem-
bly (Fig. 42).(26) Remove rear sun gear and #7 needle bearing
(Fig. 43).
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
(27) Setup tool 5058 as shown in (Fig. 44). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
Fig. 41 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
Fig. 42 Remove Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 43 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 44 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
RSAUTOMATIC - 41TE21 - 175
AUTOMATIC - 41TE (Continued)

(23) Bend tabs on strap up against flats of bolts
(Fig. 113).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 114).(25) Install bearing cup and oil baffle to transfer
shaft (Fig. 115).
(26) Using Tool 5049A, install transfer shaft (Fig.
116).
Fig. 113 Bend Tabs On Strap Up Against Flats Of
Bolts
1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP
Fig. 114 Install Transfer Shaft Bearing Cone
1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM
Fig. 115 Install Bearing Cup to Shaft
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
Fig. 116 Install Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
21 - 194 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)