2004 CHRYSLER VOYAGER Service Manual

Page 1905 of 2585

CHRYSLER VOYAGER 2004  Service Manual (38) Using tool L-4407A, remove transfer shaft
gear (Fig. 54).
(39) Remove transfer gear shim (select) (Fig. 55). (40) Remove bearing cup retainer (Fig. 56).
(41) Remove transfer gear bearing cone usi

Page 1906 of 2585

CHRYSLER VOYAGER 2004  Service Manual (42) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 58).
(43) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 59). (44) Using tool 5049A, remove transfer shaft

Page 1907 of 2585

CHRYSLER VOYAGER 2004  Service Manual (46) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 62).
(47) Bend output gear retaining strap ears flat to
allow bolt removal. (48) Remove output shaft stirrup strap bolts (Fi

Page 1908 of 2585

CHRYSLER VOYAGER 2004  Service Manual (51) Using Tool L4407A, and button 6055, remove
output gear from shaft (Fig. 67).
(52) Remove output gear bearing shim (select)
(Fig. 68). (53) Using setup as shown in (Fig. 69), remove
output gear be

Page 1909 of 2585

CHRYSLER VOYAGER 2004  Service Manual (55) Remove rear carrier assembly bearing cone
using setup shown in (Fig. 71).
(56) Install low/reverse spring compressor tool as
shown in (Fig. 72) (Fig. 73). (57) Compress low/reverse piston return

Page 1910 of 2585

CHRYSLER VOYAGER 2004  Service Manual (58) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 75).
(59) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 76). (60) Using ordinar

Page 1911 of 2585

CHRYSLER VOYAGER 2004  Service Manual (62) Remove low/reverse clutch piston (Fig. 79).
(63) Remove low/reverse piston retainer-to-case
screws (Fig. 80). (64) Remove low/reverse piston retainer (Fig. 81).
(65) Remove low/reverse piston ret

Page 1912 of 2585

CHRYSLER VOYAGER 2004  Service Manual (66) Using a hammer and suitable drift, drive out
inner output bearing cup (Fig. 83).
(67) Using tool 6062, remove outer output bearing
cup (Fig. 84).
ASSEMBLY
CAUTION: The cooler bypass valve must be