2004 CHRYSLER VOYAGER Service Manual

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Page 1897 of 2585

CHRYSLER VOYAGER 2004 Service Manual (10) Remove underdrive and overdrive accumula- tors (Fig. 22). (11) Remove low/reverse accumulator snap ring (Fig. 23). (12) Remove low/reverse accumulator plug (Fig. 24). (13) Remove low/reverse accu

Page 1898 of 2585

CHRYSLER VOYAGER 2004 Service Manual (14) Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play set and dial indicator as shown in (Fig. 27). Input shaft end play should be within 0.13-0.64 mm (0.005-0

Page 1899 of 2585

CHRYSLER VOYAGER 2004 Service Manual (17) Remove oil pump assembly (Fig. 30) (Fig. 31). (18) Remove oil pump gasket (Fig. 32).CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt

Page 1900 of 2585

CHRYSLER VOYAGER 2004 Service Manual (20) Remove #1 needle bearing (Fig. 34). (21) Remove input clutch assembly (Fig. 35).(22) Remove #4 thrust plate (Fig. 36). (23) Remove front sun gear assembly and #4 thrust washer (Fig. 37). Fig. 34

Page 1901 of 2585

CHRYSLER VOYAGER 2004 Service Manual (24) Remove front carrier/rear annulus assembly and #6 needle bearing (Fig. 38). (25) Remove rear sun gear and #7 needle bearing (Fig. 39). NOTE: The number 7 needle bearing has three anti- reversal t

Page 1902 of 2585

CHRYSLER VOYAGER 2004 Service Manual (27) Remove 2/4 clutch retainer (Fig. 42). (28) Remove 2/4 clutch return spring (Fig. 43).(29) Remove 2/4 clutch pack (Fig. 44). Tag 2/4 clutch pack for reassembly identification. (30) Remove tapered

Page 1903 of 2585

CHRYSLER VOYAGER 2004 Service Manual (31) Remove low/reverse reaction plate (Fig. 46). (32) Remove one low/reverse clutch disc (Fig. 47).(33) Remove low/reverse reaction plate snap ring (Fig. 48). (34) Remove low/reverse clutch pack (Fig

Page 1904 of 2585

CHRYSLER VOYAGER 2004 Service Manual (35) Remove transfer gear cover-to-case bolts (Fig. 50). (36) Remove transfer gear cover (Fig. 51). (37) Using Tool 6259, remove transfer shaft gear- to-shaft nut and coned washer (Fig. 52) (Fig. 53).
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