2004 CHRYSLER VOYAGER Service Manual

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Page 1601 of 2585

CHRYSLER VOYAGER 2004 Service Manual If fluid is leaking from weep hole B (Fig. 5) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input

Page 1602 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Fluid level should be within 3/16º from bottom
of inspection hole. Add MopartGear and Axle Lubri-
cant 80W-90 as necessary with suitable suction gun
(Fig. 7).
(4) Install inspection plug and torq

Page 1603 of 2585

CHRYSLER VOYAGER 2004 Service Manual (4) Remove propeller shaft assembly (Fig. 10).
(Refer to 3 - DIFFERENTIAL & DRIVELINE/PRO-
PELLER SHAFT - REMOVAL)
(5) Remove cradle plate (Fig. 11).
(6) Remove the Power Transfer Unit mounting
bracke

Page 1604 of 2585

CHRYSLER VOYAGER 2004 Service Manual ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
This procedure is used when the output flange is
replaced. Replacement of the output flange requires
installation of the correct size shim to maintain bear-
in

ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
This procedure is used when the output flange is
replaced. Replacement of the output flange requires
installation of the correct size shim to maintain bear-
ing preload.The shim must protrude from the
new output flange the same distance that the
original shim protruded from the original
flange.
(1) Stand the original output flange on end with
shim side pointing up.
(2) Place original shim into groove in top of flange.
(3) Place a straight edge across the shim.
(4) Using feeler gauge, measure the distance
between the straight edge and the top of the flange
(Fig. 15). Record this measurement.
(5) Repeat steps Step 1 through Step 4using the
new flange and the original shim.Record this
measurement.
(6) If measurements are not equal, use a new shim
that protrudes from new output flange. Make sure it
protrudes the same amount.
(7) For Example: The original shim protrudes
0.075 inch from the original output flange. Place the
original shiminto the new output flange. The pro-
trusion of the shim in the new flange is 0.085 inch.
This indicates that a 0.010 inch thinner shim is
required to maintain the original protrusion.(8) Install output flange and torque flange nut to
244 N´m (180 ft. lbs.).
(9) Check the turning torque of the pinion before
installing the rear cover into the P.T.U. The turning
torque should be between 2.0 N´m and 2.5 N´m (17
in. lbs. and 22 in. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION...................TORQUE
End Cover................ 28N´m(250 in. lbs.)
Fill Plug................. 27N´m(240 in. lbs.)
Flange Nut............... 162N´m(120 ft. lbs.)
Inspection Plug............ 20N´m(180 in. lbs.)
Rear Cover............... 28N´m(250 in. lbs.)
Ring Gear................. 94N´m(70ft.lbs.)
Fig. 14 P.T.U. Upper Mounting Bolts
1 - P.T.U. UPPER MOUNTING BOLTS
2 - P.T.U.
Fig. 15 Output Flange Shim Measurement
1 - MEASURE THIS DIMENSION
2 - SHIM
3 - O-RING
4 - OUTPUT FLANGE
RSPOWER TRANSFER UNIT21-7
POWER TRANSFER UNIT (Continued)

Page 1605 of 2585

CHRYSLER VOYAGER 2004 Service Manual SPECIAL TOOLS
SDP POWER TRANSFER UNIT
5049-a Seal Puller
5065 Bearing Installer
6514 Bearing Remover
6522 Bearing Remover
7794-a Bearing Remover
C-4171 Handle
C-4171-2 Handle
C-4657 Seal Installer
MD9

Page 1606 of 2585

CHRYSLER VOYAGER 2004 Service Manual DIFFERENTIAL CARRIER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
(1) Remove P.T.U. from vehicle.
(2) Use a pry bar to remove seal from retainer
plate (F

Page 1607 of 2585

CHRYSLER VOYAGER 2004 Service Manual (4) Remove bearing retaining snap ring (Fig. 18).
(5) Use bearing puller MD998346 to remove bear-
ing (Fig. 19).
INSTALLATION
The end cover ball bearing can be removed and
installed without removing t

Page 1608 of 2585

CHRYSLER VOYAGER 2004 Service Manual END COVER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to perform this operation. (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL)
(1) Remove P.T.U. end co

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