2004 CHRYSLER VOYAGER Service Manual

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Page 1697 of 2585

CHRYSLER VOYAGER 2004 Service Manual INTERMEDIATE SHAFT DESCRIPTION The intermediate shaft assembly (Fig. 227) is part of the transaxle geartrain, meshes with and is driven by the input shaft, drives the differential via an inte- grated

Page 1698 of 2585

CHRYSLER VOYAGER 2004 Service Manual (2) Install 8486-4 button to intermediate shaft. Using arbor press ram, press reverse gear and inter- mediate roller bearing off of shaft, while holding remaining assembly with hand (Fig. 228). (3) Re

Page 1699 of 2585

CHRYSLER VOYAGER 2004 Service Manual (7) Remove 5th gear blocker ring (Fig. 232). (8) Remove 5th gear and needle bearing (if equipped) (Fig. 233).(9) Remove 3/4 cluster gear snap ring (Fig. 234). (10) Install shaft assembly into fixture

Page 1700 of 2585

CHRYSLER VOYAGER 2004 Service Manual (11) Using an arbor press, press intermediate shaft out of 3/4 cluster gear (Fig. 237). (12) Remove intermediate shaft from fixture and remove 3/4 cluster gear from shaft (Fig. 238). (13) Remove 2nd g

Page 1701 of 2585

CHRYSLER VOYAGER 2004 Service Manual (14) Remove 2nd gear reactor ring (Fig. 240). (15) Remove 2nd gear friction cone (Fig. 241).(16) Remove 2nd Gear outer blocker ring (Fig. 242). (17) Remove 1/2 synchro snap ring (Fig. 243). Fig. 240 2

Page 1702 of 2585

CHRYSLER VOYAGER 2004 Service Manual (18) Remove 1/2 synchro from shaft (Fig. 244). (19) Remove 1st gear blocker ring (Fig. 245).(20) Remove 1st gear friction cone (Fig. 246). (21) Remove 1st gear reactor ring (Fig. 247). Fig. 244 1/2 Sy

Page 1703 of 2585

CHRYSLER VOYAGER 2004 Service Manual (22) Remove 1st gear from shaft (Fig. 248). (23) Remove 1st gear needle bearing (Fig. 249). (24) Remove intermediate shaft roller bearing snap ring (Fig. 250). (25) Press intermediate shaft out of rol

Page 1704 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY NOTE: Depending on date of transaxle manufacture, some intermediate shafts will utilize a needle bear- ing under 2nd and 5th Speed Gears. NOTE: Do not re-use snap rings when servicing the int
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