2004 CHRYSLER VOYAGER Service Manual

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Page 1921 of 2585

CHRYSLER VOYAGER 2004 Service Manual (27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 114).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 115). (29) Install bearing cup retainer to transa

Page 1922 of 2585

CHRYSLER VOYAGER 2004 Service Manual (31)TRANSFER GEAR BEARING ADJUST-
MENT: (a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 118). (b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install trans

(31)TRANSFER GEAR BEARING ADJUST-
MENT: (a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 118). (b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install transfer shaft gear retain-
ing nut to 271 N´m (200 ft. lbs.). (c) Measure end play. Attach Tool L4432 to the
transfer gear. (d) Mount a steel ball with grease into the end
of the transfer shaft. (e) Push and pull the gear while rotating back
and forth to ensure seating of the bearing rollers. (f) Using a dial indicator, measure transfer shaft
end play. (g) Refer to the transfer shaft bearing shim
chart for the required shim combination to obtain
the proper bearing setting. (h) Use Tool 6259 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L4407A. (i) Remove the gauging shim (Fig. 118) and
install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm (0.002 in.) 4.66mm (0.183
in.) 4505588AB 0.76mm (0.030
in.) 3.94mm (0.155
in.) 4412818AB
0.08mm (0.003 in.) 4.62mm (0.182
in.) 4412835AB 0.79mm (0.031
in.) 3.90mm (0.154
in.) 4412817AB
0.10mm (0.004 in.) 4.58mm (0.180
in.) 4412834AB 0.81mm (0.032
in.) 3.90mm (0.154
in.) 4412817AB
0.13mm (0.005 in.) 4.58mm (0.180
in.) 4412834AB 0.84mm (0.033
in.) 3.86mm (0.152
in.) 4412816AB
0.15mm (0.006 in.) 4.54mm (0.178
in.) 4412833AB 0.86mm (0.034
in.) 3.82mm (0.150
in.) 4412815AB
0.18mm (0.007 in.) 4.50mm (0.177
in.) 4412832AB 0.89mm (0.035
in.) 3.82mm (0.150
in.) 4412815AB
0.20mm (0.008 in.) 4.50mm (0.177
in.) 4412832AB 0.91mm (0.036
in.) 3.78mm (0.149
in.) 4412814AB
0.23mm (0.009 in.) 4.46mm (0.175
in.) 4412831AB 0.94mm (0.037
in.) 3.74mm (0.147
in.) 4412813AB
0.25mm (0.010 in.) 4.46mm (0.175
in.) 4412831AB 0.97mm (0.038
in.) 3.74mm (0.147
in.) 4412813AB
0.28mm (0.011 in.) 4.42mm (0.174
in.) 4412830AB 0.99mm (0.039
in.) 3.70mm (0.146
in.) 4412812AB
0.30mm (0.012 in.) 4.38mm (0.172
in.) 4412829AB 1.02mm (0.040
in.) 3.66mm (0.144
in.) 4412811AB
0.33mm (0.013 in.) 4.38mm (0.172
in.) 4412829AB 1.04mm (0.041
in.) 3.66mm (0.144
in.) 4412811AB
Fig. 118 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
RS 40TE AUTOMATIC TRANSAXLE21s-61
40TE AUTOMATIC TRANSAXLE (Continued)

Page 1923 of 2585

CHRYSLER VOYAGER 2004 Service Manual End Play Shim Needed Part Number End Play Shim Needed Part Number
0.36mm (0.014 in.) 4.34mm (0.171
in.) 4412828AB 1.07mm (0.042
in.) 3.62mm (0.143
in.) 4412810AB
0.38mm (0.015 in.) 4.30mm (0.169
in.)

Page 1924 of 2585

CHRYSLER VOYAGER 2004 Service Manual (32) Install the transfer shaft gear using Tool 6261
(Fig. 119).
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 1925 of 2585

CHRYSLER VOYAGER 2004 Service Manual (38) Install low/reverse clutch pack (Fig. 123).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 124). (40) Install remaining low/re

Page 1926 of 2585

CHRYSLER VOYAGER 2004 Service Manual (42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 127) (Fig. 128).
(43) Set up dial indicator as shown in (Fig. 129) to
measure low/reverse clutch clearance. Press down on
clutch

Page 1927 of 2585

CHRYSLER VOYAGER 2004 Service Manual NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.(45) Orient 2/4 clutch return spring to retainer as

Page 1928 of 2585

CHRYSLER VOYAGER 2004 Service Manual (49) Install rear sun gear and #7 needle bearing
(Fig. 136).
NOTE: The number seven needle bearing has three
anti-reversal tabs and is common with the number
five and number two position. The orientat

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