2001 CHRYSLER VOYAGER Service Manual

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Page 3097 of 4284

CHRYSLER VOYAGER 2001 Service Manual (10) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(11) Use Tool L-4434 to remove the retaining nut
and washer. To remove the outpu

(10) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out-
put shaft bearings.
(11) Use Tool L-4434 to remove the retaining nut
and washer. To remove the output shaft gear use Tool
L-4407.
(12) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to
hold the shims in place. Install the output shaft gear
and bearing assembly.(13) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.).
(14) Using an inch-pound torque wrench, check the
turning torque.The torque should be between 3
and 8 inch-pounds.
(15) If the turning torque is too high, install a
0.05mm (0.002 inch) thicker shim. If the turning
torque is too low, install a 0.05 mm (0.002 inch) thin-
ner shim. Repeat until the proper turning torque is 3
to 8 inch pounds.
OUTPUT SHAFT BEARING SHIM CHART
End Play (with 13.65 mm and
1.34 mm gauging shims
installed)Required Shim Combination Total Thickness
mm inch mm mm inch
.0 .0 13.65 + 1.34 14.99 .590
.05 .002 13.65 + 1.24 14.89 .586
.10 .004 13.65 + 1.19 14.84 .584
.15 .006 13.65 + 1.14 14.79 .582
.20 .008 13.65 + 1.09 14.74 .580
.25 .010 13.65 + 1.04 14.69 .578
.30 .012 13.65 + .99 14.64 .576
.35 .014 13.65 + .94 14.59 .574
.40 .016 13.15 + 1.39 14.54 .572
.45 .018 13.15 + 1.34 14.49 .570
.50 .020 13.15 + 1.29 14.44 .568
.55 .022 13.15 + 1.24 14.39 .566
.60 .024 13.15 + 1.19 14.34 .564
.65 .026 13.15 + 1.14 14.29 .562
.70 .028 13.15 + 1.09 14.24 .560
.75 .030 13.15 + 1.04 14.19 .558
.80 .032 13.15 + .99 14.14 .556
.85 .034 13.15 + .94 14.09 .554
.90 .036 12.65 + 1.39 14.04 .552
.95 .038 12.65 + 1.34 13.99 .550
1.00 .040 12.65 + 1.29 13.94 .548
1.05 .042 12.65 + 1.24 13.89 .547
1.10 .044 12.65 + 1.19 13.84 .545
1.15 .046 12.65 + 1.14 13.79 .543
1.20 .048 12.65 + 1.09 13.74 .541
1.25 .049 12.65 + 1.04 13.69 .539
1.30 .051 12.65 + .99 13.64 .537
1.35 .053 12.65 + .94 13.59 .535
RSAUTOMATIC - 31TH21 - 133
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING (Continued)

Page 3098 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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. Clea

Page 3099 of 4284

CHRYSLER VOYAGER 2001 Service Manual (7) Using Tool L-4407A, remove transfer shaft gear
and select shim (Fig. 269).
(8) Using Tool L-4406-1 and adapter L-4406-3,
remove transfer shaft gear bearing cone (Fig. 270).(9) Remove governor supp

Page 3100 of 4284

CHRYSLER VOYAGER 2001 Service Manual (11) If necessary, remove low/reverse band anchor
pin (Fig. 273).
(12) Remove governor assembly (Fig. 274).(13) Remove transfer shaft bearing retainer snap
ring (Fig. 275).
(14) Set up tools as shown

Page 3101 of 4284

CHRYSLER VOYAGER 2001 Service Manual (15) Remove transfer shaft/bearing retainer assem-
bly (Fig. 277).
(16) Separate bearing retainer from transfer shaft
(Fig. 278).
(17) Remove transfer shaft bearing cone from shaft
using Tool C-293-PA

Page 3102 of 4284

CHRYSLER VOYAGER 2001 Service Manual (4) Install transfer shaft/bearing retainer assembly
using tool L-4512 (Fig. 284).
(5) Install transfer shaft bearing retainer snap
ring (Fig. 285).
(6) Install governor assembly (Fig. 286).
Fig. 281

Page 3103 of 4284

CHRYSLER VOYAGER 2001 Service Manual (7) Install low/reverse band anchor pin if previ-
ously removed (Fig. 287).
(8) Install governor support retainer bearing cup
using Tool L-4520 (Fig. 288).
Fig. 285 Transfer Shaft Bearing Snap Ring
1

Page 3104 of 4284

CHRYSLER VOYAGER 2001 Service Manual (9) Install governor support retainer (Fig. 289).
(10) Install transfer shaft gear bearing cone using
Tool L-4410 (Fig. 290).
(11) Determine transfer shaft bearing shim thick-
ness. (Refer to 21 - TRA

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