2004 CHRYSLER VOYAGER Service Manual

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Page 1753 of 2585

CHRYSLER VOYAGER 2004 Service Manual (32) Install the transfer shaft gear using Tool 6261 (Fig. 121). CAUTION: Install a NEW retaining nut, as the origi- nal nut MUST NOT be reused. (33) Install the new retaining nut and washer. (34) Usi

Page 1754 of 2585

CHRYSLER VOYAGER 2004 Service Manual (38) Install low/reverse clutch pack (Fig. 125). Leave uppermost disc out until snap ring is installed. (39) Install low/reverse reaction plate flat snap ring (Fig. 126).(40) Install remaining low/rev

Page 1755 of 2585

CHRYSLER VOYAGER 2004 Service Manual (42) Install tapered snap ring (with tapered side up) as shown in (Fig. 129) (Fig. 130). (43) Set up dial indicator as shown in (Fig. 131) to measure low/reverse clutch clearance. Press down on clutch

Page 1756 of 2585

CHRYSLER VOYAGER 2004 Service Manual (46) Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig. 135).(47) Install snap ring. (48) Set up dial indicator as shown in (Fig. 136) and measure 2/4 clutch cle

Page 1757 of 2585

CHRYSLER VOYAGER 2004 Service Manual (49) Install rear sun gear and #7 needle bearing (Fig. 138). NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientat

Page 1758 of 2585

CHRYSLER VOYAGER 2004 Service Manual (d) Install pump and gasket to transmission. Install and torque bolts. (e) Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in (Fig. 144). (f) Measure the inp

Page 1759 of 2585

CHRYSLER VOYAGER 2004 Service Manual NO. 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431665AB 1.60mm (0.063 in.) 3836237AB 1.73mm (0.068 in.) 4431666AB 1.80mm (0.071 in.) 3836238AB 1.96mm (0.077 in.) 4431667AB 2.03mm (0.080 in.) 3836239A

Page 1760 of 2585

CHRYSLER VOYAGER 2004 Service Manual (57) Install oil pump assembly (Fig. 149). (58) Install oil pump-to-case bolts and torque to 27 N´m (20 ft. lbs.) (Fig. 150).(59) Install low/reverse accumulator (Fig. 151). (60) Install low/reverse
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