2004 CHRYSLER VOYAGER Service Manual

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Page 1729 of 2585

CHRYSLER VOYAGER 2004 Service Manual (21) Remove #1 needle bearing (Fig. 36). (22) Remove input clutch assembly (Fig. 37).(23) Remove #4 thrust plate (Fig. 38). (24) Remove front sun gear assembly and #4 thrust washer (Fig. 39). Fig. 36

Page 1730 of 2585

CHRYSLER VOYAGER 2004 Service Manual (25) Remove front carrier/rear annulus assembly and #6 needle bearing (Fig. 40). (26) Remove rear sun gear and #7 needle bearing (Fig. 41). NOTE: The number 7 needle bearing has three anti- reversal t

Page 1731 of 2585

CHRYSLER VOYAGER 2004 Service Manual (28) Remove 2/4 clutch retainer (Fig. 44). (29) Remove 2/4 clutch return spring (Fig. 45).(30) Remove 2/4 clutch pack (Fig. 46).Tag 2/4 clutch pack for reassembly identification. (31) Remove tapered s

Page 1732 of 2585

CHRYSLER VOYAGER 2004 Service Manual (32) Remove low/reverse reaction plate (Fig. 48). (33) Remove one low/reverse clutch disc (Fig. 49).(34) Remove low/reverse reaction plate snap ring (Fig. 50). (35) Remove low/reverse clutch pack (Fig

Page 1733 of 2585

CHRYSLER VOYAGER 2004 Service Manual (36) Remove transfer gear cover-to-case bolts (Fig. 52). (37) Remove transfer gear cover (Fig. 53).(38) Using Tool 6259, remove transfer shaft gear- to-shaft nut and coned washer (Fig. 54) (Fig. 55).

Page 1734 of 2585

CHRYSLER VOYAGER 2004 Service Manual (39) Using tool L-4407A, remove transfer shaft gear (Fig. 56). (40) Remove transfer gear shim (select) (Fig. 57).(41) Remove bearing cup retainer (Fig. 58). (42) Remove transfer gear bearing cone usin

Page 1735 of 2585

CHRYSLER VOYAGER 2004 Service Manual (43) Remove transfer shaft bearing cup from retainer using Tool 6062 (Fig. 60). (44) Using Tool 6051, remove transfer shaft bear- ing snap ring (Fig. 61).(45) Using tool 5049A, remove transfer shaft f

Page 1736 of 2585

CHRYSLER VOYAGER 2004 Service Manual (47) Using tool P-334, press transfer shaft bearing cone off of shaft (Fig. 64). (48) Bend output gear retaining strap ears flat to allow bolt removal. (49) Remove output shaft stirrup strap bolts (Fi
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