2003 CHRYSLER CARAVAN Service Manual

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Page 1577 of 2177

CHRYSLER CARAVAN 2003 Service Manual (14) Remove low/reverse accumulator (Fig. 28). (15) Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play set and dial indicator as shown in (Fig. 29).Input shaft e

Page 1578 of 2177

CHRYSLER CARAVAN 2003 Service Manual (18) Remove oil pump assembly (Fig. 32) (Fig. 33). (19) Remove oil pump gasket (Fig. 34). CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt

Page 1579 of 2177

CHRYSLER CARAVAN 2003 Service Manual (21) Remove #1 needle bearing (Fig. 36). (22) Remove input clutch assembly (Fig. 37).(23) Remove #4 thrust plate (Fig. 38). (24) Remove front sun gear assembly and #4 thrust washer (Fig. 39). Fig. 36

Page 1580 of 2177

CHRYSLER CARAVAN 2003 Service Manual (25) Remove front carrier/rear annulus assembly and #6 needle bearing (Fig. 40). (26) Remove rear sun gear and #7 needle bearing (Fig. 41). NOTE: The number 7 needle bearing has three anti- reversal t

Page 1581 of 2177

CHRYSLER CARAVAN 2003 Service Manual (28) Remove 2/4 clutch retainer (Fig. 44). (29) Remove 2/4 clutch return spring (Fig. 45).(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4 clutch pack for reassembly identification. (31) Remove tapered s

Page 1582 of 2177

CHRYSLER CARAVAN 2003 Service Manual (32) Remove low/reverse reaction plate (Fig. 48). (33) Remove one low/reverse clutch disc (Fig. 49).(34) Remove low/reverse reaction plate snap ring (Fig. 50). (35) Remove low/reverse clutch pack (Fig

Page 1583 of 2177

CHRYSLER CARAVAN 2003 Service Manual (36) Remove transfer gear cover-to-case bolts (Fig. 52). (37) Remove transfer gear cover (Fig. 53).(38) Using Tool 6259, remove transfer shaft gear- to-shaft nut and coned washer (Fig. 54) (Fig. 55).

Page 1584 of 2177

CHRYSLER CARAVAN 2003 Service Manual (39) Using tool L-4407A, remove transfer shaft gear (Fig. 56). (40) Remove transfer gear shim (select) (Fig. 57).(41) Remove bearing cup retainer (Fig. 58). (42) Remove transfer gear bearing cone usin
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