2002 CHRYSLER VOYAGER Service Manual

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Page 1649 of 2399

CHRYSLER VOYAGER 2002 Service Manual (5) Remove differential cover (Fig. 141). Clean sur-
faces of old adhesive prior to reassembly.
(6) Remove bearing retainer axle seal using slide
hammer C-637 and Tool 7794A, or Tool L-4518.
(7) Remov

Page 1650 of 2399

CHRYSLER VOYAGER 2002 Service Manual (12) Remove differential bearing cone (from exten-
sion housing side) using Tool C-293, and adapters
C-293-3, and C-293-36 (Fig. 146).(13) Set up tools as shown in (Fig. 147) and (Fig.
148) to facilit

Page 1651 of 2399

CHRYSLER VOYAGER 2002 Service Manual (14) Remove differential bearing cone (Fig. 149).
(15) Remove bearing retainer bearing cup using
Tool 6062A (Fig. 150) (Fig. 151). Remove shim and oil
baffle.
ASSEMBLY
NOTE: The differential is servic

Page 1652 of 2399

CHRYSLER VOYAGER 2002 Service Manual (2) Position bearing cone onto differential (Fig.
153), and install bearing cone using Tool 6536 and
driver handle C-4171 (Fig. 154).(3) Measure side gear end play using dial indicator
C-3339 and Tool

Page 1653 of 2399

CHRYSLER VOYAGER 2002 Service Manual (4) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant to the adapter plate. Load differential
assembly into position and install adapter plate.
(5) Using Tool L-4435, index adapter plate until

Page 1654 of 2399

CHRYSLER VOYAGER 2002 Service Manual (11) Install adapter plate axle seal using Tool
L-4520 (inverted), and driver handle C-4171.
(12) Check differential turning torque. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/BEARINGS - A

Page 1655 of 2399

CHRYSLER VOYAGER 2002 Service Manual (4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 164).Turning torque should be within 5±18
in. lbs.
(5) If the turning torque is within speci

Page 1656 of 2399

CHRYSLER VOYAGER 2002 Service Manual FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LE

FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LEVEL CHECK
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the fluid level indicator (Fig. 165).
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from thetransaxle dipstick where it may be mistaken for a
leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. MopartATF+4 (Automatic
Transmission Fluid-Type 9602) when new is red in
color. The ATF is dyed red so it can be identified from
other fluids used in the vehicle such as engine oil or
antifreeze. The red color is not permanent and is not
an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
ATF+4 also has a unique odor that may change with
age. Consequently,odor and color cannot be used
to indicate the fluid condition, or the need for a
fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
CHANGE
NOTE: For the recommended maintenance (fluid/fil-
ter change) intervals for this transaxle, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) Type 9602 should
be used. A filter change should be made at the time
of the transmission oil change. The magnet (on the
inside of the oil pan) should also be cleaned with a
clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Place a drain con-
tainer with a large opening, under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Remove oil filter-to-valve body screws (Fig.
166).
(4) Remove oil filter and gasket (Fig. 167).
(5) Install a new filter and gasket (Fig. 167).
(6) Clean the oil pan and magnet. Reinstall pan
using new MopartSilicone Rubber Adhesive Sealant.
Torque oil pan bolts to 19 N´m (165 in. lbs.).
(7) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid-Type 9602) through the dipstick
opening.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
RS31TH AUTOMATIC TRANSAXLE21-99
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