2004 CHRYSLER VOYAGER Service Manual

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Page 1873 of 2585

CHRYSLER VOYAGER 2004 Service Manual (9) Remove 3/4 cluster gear snap ring (Fig. 35). (10) Install shaft assembly into fixture 8483, with split collar 8483-3 oriented chamfer side up (Fig. 36). Place 8483-2 into position with chamfer sid

Page 1874 of 2585

CHRYSLER VOYAGER 2004 Service Manual (12) Remove intermediate shaft from fixture and remove 3/4 cluster gear from shaft (Fig. 39). (13) Remove 2nd gear and needle bearing (Fig. 40) (Fig. 41). (14) Remove 2nd gear reactor ring (Fig. 42).

Page 1875 of 2585

CHRYSLER VOYAGER 2004 Service Manual (15) Remove 2nd gear friction cone (Fig. 43). (16) Remove 2nd Gear outer blocker ring (Fig. 44).(17) Remove 1/2 synchro snap ring (Fig. 45). (18) Remove 1/2 synchro from shaft (Fig. 46). Fig. 43 2nd G

Page 1876 of 2585

CHRYSLER VOYAGER 2004 Service Manual (19) Remove 1st gear blocker ring (Fig. 47). (20) Remove 1st gear friction cone (Fig. 48).(21) Remove 1st gear reactor ring (Fig. 49). (22) Remove 1st gear from shaft (Fig. 50). Fig. 47 1st Gear Block

Page 1877 of 2585

CHRYSLER VOYAGER 2004 Service Manual (23) Remove 1st gear needle bearing (Fig. 51). (24) Remove first gear thrust bearing (Fig. 52). (25) Remove intermediate shaft roller bearing snap ring (Fig. 53). (26) Press intermediate shaft out of

Page 1878 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY NOTE: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard snap rings and install new ones provided with available snap ring service kit. NOTE: When installing 1/2

Page 1879 of 2585

CHRYSLER VOYAGER 2004 Service Manual (2) Install intermediate shaft roller bearing snap ring (Fig. 57). (3) Install 1st gear thrust bearing (Fig. 58). (4) Install 1st gear needle bearing to intermediate shaft (Fig. 59). (5) Install 1st g

Page 1880 of 2585

CHRYSLER VOYAGER 2004 Service Manual (6) Install 1/2 synchro to fixture 8483. Insert 1st gear blocker ring, friction cone, and reactor ring as shown in (Fig. 61). (7) Install intermediate shaft to synchro assembly on fixture (Fig. 62). W
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