2004 CHRYSLER VOYAGER Service Manual

Page 1609 of 2585

CHRYSLER VOYAGER 2004  Service Manual HALF SHAFT INNER SEAL
REMOVAL
The power transfer unit half shaft inner seal is the
smaller of the two seals located on the inside of the
end cover.
(1) Remove power transfer unit from the vehicle.
(2)

Page 1610 of 2585

CHRYSLER VOYAGER 2004  Service Manual (4) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 29). Retighten first bolt after
all other bolts are tight.
(5) Reinstall

Page 1611 of 2585

CHRYSLER VOYAGER 2004  Service Manual INSTALLATION
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1

Page 1612 of 2585

CHRYSLER VOYAGER 2004  Service Manual (3) Reinstall the original bearing race and shim
using special tool No. 6522 (Fig. 35) and (Fig. 36).
CAUTION: The original shim must be installed behind
the bearing cup to maintain proper bearing pre

Page 1613 of 2585

CHRYSLER VOYAGER 2004  Service Manual (3) Tap on end cover ears to separate end cover
from case (Fig. 39).
(4) Pry out seal with a pry bar (Fig. 40).INSTALLATION
The input shaft end seal is located on the end of
the input shaft.
(1) Clean

Page 1614 of 2585

CHRYSLER VOYAGER 2004  Service Manual INPUT SHAFT SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cov

Page 1615 of 2585

CHRYSLER VOYAGER 2004  Service Manual INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Clean and inspect seal area.
(2)

Page 1616 of 2585

CHRYSLER VOYAGER 2004  Service Manual OUTER HALF SHAFT SEAL
REMOVAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Lift vehicle on hoist.
(2) Remove r