2004 CHRYSLER VOYAGER Service Manual

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Page 1865 of 2585

CHRYSLER VOYAGER 2004 Service Manual (9) Remove 3/4 synchronizer snap ring (Fig. 8). Discard and replace with new snap ring upon assem- bly. (10) Remove 3/4 synchronizer (Fig. 9). (11) Remove 3rd gear blocker ring (Fig. 10). (12) Remove

Page 1866 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY NOTE: When servicing the input shaft assembly, all snap rings MUST be replaced with new ones upon assembly. 5th gear nut must also be replaced. NOTE: When installing 3/4 synchronizer hub to s

Page 1867 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Install 3rd gear and needle bearing (Fig. 14) (Fig. 15). (4) Install 3rd gear blocker ring (Fig. 16). (5) Install 3/4 synchronizer (Fig. 17). When installing 3/4 synchronizer hub to shaft, make su

Page 1868 of 2585

CHRYSLER VOYAGER 2004 Service Manual (6) InstallNEW3/4 synchronizer snap ring (Fig. 18). (7) Install 4th gear blocker ring (Fig. 19). (8) Install 4th gear and needle bearing (Fig. 20) (Fig. 21). Fig. 18 3/4 Synchro Snap Ring 1 - SNAP RIN

Page 1869 of 2585

CHRYSLER VOYAGER 2004 Service Manual (9) Install 5th gear and press into position using installer 8481 (Fig. 22). (10) Install NEW5th gear nut and torque to 262 N´m (193 ft. lbs.) using wrench 8478 (Fig. 23). (11) Stake 5th Gear nut in

Page 1870 of 2585

CHRYSLER VOYAGER 2004 Service Manual (e) Loosen staking screws and thumb screws. Remove tool and visually inspect stake (Fig. 26). (f) Remove tool, rotate 90É, and repeat process to stake in four (4) places. NOTE: The input shaft sealed

Page 1871 of 2585

CHRYSLER VOYAGER 2004 Service Manual ²1/2 Synchronizer ² 5/R Synchronizer The intermediate shaft is supported by a caged roller bearing at the front of the transaxle, and a sealed roller bearing at the rear of the transaxle. DISASSEMBL

Page 1872 of 2585

CHRYSLER VOYAGER 2004 Service Manual (6) Remove 5/R synchro (Fig. 31). (7) Remove 5th gear blocker ring (Fig. 32).(8) Remove 5th gear and needle bearing (Fig. 33) (Fig. 34). Fig. 31 5/R Synchronizer 1 - 5/R SYNCHRO ASSEMBLY Fig. 32 5th G
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