2004 CHRYSLER VOYAGER Service Manual

Page 1641 of 2585

CHRYSLER VOYAGER 2004  Service Manual (6) Install lifting bar 8489 to geartrain. Install
geartrain to case.When installing geartrain to
case, use care not to damage bearing surfaces.
(7) Remove lifting bar 8489 from geartrain.
(8) Install

Page 1642 of 2585

CHRYSLER VOYAGER 2004  Service Manual Fig. 54 Install Reverse Idler Gear Bearing
1 - NEEDLE BEARING
2 - REVERSE IDLER SHAFT
Fig. 55 Install Reverse Idler Gear
1 - REVERSE IDLER GEAR
Fig. 56 Install Flat Washer
1 - FLAT WASHER
Fig. 57 Inst

Page 1643 of 2585

CHRYSLER VOYAGER 2004  Service Manual (14) Install input shaft sealed roller bearing using
installer 8482 (Fig. 58).
(15) Installnewinput shaft bearing snap ring
(Fig. 59).(16) Install shift rail bushing to end cover using
installer 8475

Page 1644 of 2585

CHRYSLER VOYAGER 2004  Service Manual (18) Install lifting bar 8489 to geartrain.
(19) Lift up on bar (input shaft side) and install
input shaft bearing snap ring (Fig. 64).
(20) Lift up on bar (intermediate shaft side) and
install interm

Page 1645 of 2585

CHRYSLER VOYAGER 2004  Service Manual (23) Install back up lamp switch and torque to 23
N´m (17 ft. lbs.) (Fig. 66).
(24) Roll transaxle assembly on side.
(25) Install differential chip collector magnet (Fig.
67). Retain to case with a d

Page 1646 of 2585

CHRYSLER VOYAGER 2004  Service Manual (29) Install both axle output shaft seals using
driver handle C-4171 and installer 8476 (Fig. 70)
(Fig. 71).(30) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to shift cover assembly. Place shift c

Page 1647 of 2585

CHRYSLER VOYAGER 2004  Service Manual (32) If previously removed, install clutch release
lever pivot ball(s) using slide hammer C-3752 and
remover/installer 6891 (Fig. 74) (Fig. 75).
(33) Install clutch release bearing to lever. Apply
gre

Page 1648 of 2585

CHRYSLER VOYAGER 2004  Service Manual INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Rais