2004 CHRYSLER VOYAGER Service Manual

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Page 1633 of 2585

CHRYSLER VOYAGER 2004 Service Manual Fig. 25 Transaxle Removal/Installation 1 - TRANSAXLE 2 - BOLT Fig. 26 Release Bearing and Lever 1 - RELEASE LEVER 2 - RELEASE BEARING Fig. 27 Pivot Ball Orientation 1 - PIVOT BALL (1) 21 - 36 T850 MAN

Page 1634 of 2585

CHRYSLER VOYAGER 2004 Service Manual (2) Remove input shaft bearing retainer (Fig. 29). NOTE: Place transaxle in neutral before shift cover removal.(3) Remove shift cover-to-case bolts and remove shift cover assembly (Fig. 30). (4) Using

Page 1635 of 2585

CHRYSLER VOYAGER 2004 Service Manual (5) Remove extension housing-to-case and differen- tial cover bolts (Fig. 32). (6) Place transaxle with bellhousing surface down. (7) Remove backup lamp switch (Fig. 33).(8) Remove end plate (Fig. 34)

Page 1636 of 2585

CHRYSLER VOYAGER 2004 Service Manual (12) Remove lifting bar 8489. (13) Remove end cover-to-case bolts (12) (Fig. 36). (14) Remove end cover from transaxle (Fig. 37).(15) Remove 3/4 shift rail bushing from end cover using slide hammer C-

Page 1637 of 2585

CHRYSLER VOYAGER 2004 Service Manual (17) Remove 1-2/5-R shift rail (Fig. 40). (18) Install lifting bar 8489. (19) Lift geartrain (w/reverse idler gear assy.) out of transaxle and install on fixture 8487 (Fig. 41). (20) Remove remaining

Page 1638 of 2585

CHRYSLER VOYAGER 2004 Service Manual (27) Remove differential chip collector magnet and clean (Fig. 43).Magnet is adhered with RTV, and may require force to remove. (28) Remove intermediate shaft bearing race with puller 8472 (Fig. 44).(

Page 1639 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY NOTE: When assembling this transaxle, always use NEW snap rings. NOTE: Before assembling transaxle, differential turning torque must be measured and adjusted. (Refer to 21 - TRANSMISSION/TRAN

Page 1640 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Install intermediate shaft bearing race to case with an arbor press, driver handle C-4171, and installer 8471 (Fig. 49). Press until installer 8471 bottoms on transaxle case. NOTE: If input shaft
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