2004 CHRYSLER VOYAGER Service Manual

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Page 1689 of 2585

CHRYSLER VOYAGER 2004 Service Manual (7) Install cupholder plugs (Fig. 202). (8) Install gearshift boot to console (Fig. 203). Secure with three (3) retainer clips.(9) Install gearshift knob to gearshift lever (Fig. 204). Orient shift pa

Page 1690 of 2585

CHRYSLER VOYAGER 2004 Service Manual INPUT SHAFT DESCRIPTION The input shaft assembly (Fig. 205) is part of the transaxle geartrain, is driven by the clutch assembly, and consists of the following components: ²Input Mainshaft ²3rd Spee

Page 1691 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Remove input bearing. Place input shaft assembly onto arbor press table, with the input bear- ing supported by bearing splitter (Fig. 207). Using adapter 8486-4, press bearing off of shaft, while

Page 1692 of 2585

CHRYSLER VOYAGER 2004 Service Manual (8) Remove 4th gear blocker ring (Fig. 210). (9) Remove 3/4 synchronizer snap ring (Fig. 211). Discard and replace with new snap ring upon assem- bly.(10) Remove 3/4 synchronizer (Fig. 212). (11) Remo

Page 1693 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY NOTE: Depending on date of manufacture, some input shafts will utilize a needle bearing under the 3rd and 4th Speed Gears. NOTE: When servicing the input shaft assembly, all snap rings MUST b

Page 1694 of 2585

CHRYSLER VOYAGER 2004 Service Manual (1) Install input shaft into fixture 8487. (2) Install thrust washer if removed upon disas- sembly. (3) Install 3rd gear and needle bearing (if equipped) (Fig. 216). (4) Install 3rd gear blocker ring

Page 1695 of 2585

CHRYSLER VOYAGER 2004 Service Manual (7) Install 4th gear blocker ring (Fig. 220). (8) Install 4th gear and needle bearing (if equipped) (Fig. 221). (9) Install 5th gear and press into position using installer 8481 (Fig. 222).(10) Instal

Page 1696 of 2585

CHRYSLER VOYAGER 2004 Service Manual (11) Stake 5th Gear nut in four (4) places as fol- lows: (a) Install staking tool 8479 to 5th gear nut. (b) Tighten upper thumb screw by hand (Fig. 224). (c) Tighten two (2) side thumb screws by hand.
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