2004 CHRYSLER VOYAGER Service Manual

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Page 1977 of 2585

CHRYSLER VOYAGER 2004 Service Manual ASSEMBLY Use petrolatum on all seals to ease assembly of components. (1) Using an arbor press, install input shaft to input shaft hub (Fig. 213). (2) Install input shaft snap ring (Fig. 214). (3) Usin

Page 1978 of 2585

CHRYSLER VOYAGER 2004 Service Manual (4) Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig. 217). (5) Install the input hub/shaft assy. to the OD/Re- verse piston/clutch retainer assy. (Fig. 218). (6) I

Page 1979 of 2585

CHRYSLER VOYAGER 2004 Service Manual Fig. 220 Input Clutch Hub, Retainer, and OD/Reverse Piston 1 - SNAP RING (INPUT SHAFT) 2 - SNAP RING 3 - CLUTCH RETAINER 4 - SEAL, OUTER 5 - SEAL, INNER 6 - OD/REVERSE PISTON7 - SEAL, INPUT SHAFT 8 -

Page 1980 of 2585

CHRYSLER VOYAGER 2004 Service Manual (7) Install UD clutch piston (Fig. 221). (8) Install UD piston return spring and Tool 5067 as shown in (Fig. 222). (9) Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring

Page 1981 of 2585

CHRYSLER VOYAGER 2004 Service Manual Fig. 225 Underdrive Clutch Piston, Spring and Retainer 1 - SNAP RING 2 - SPRING RETAINER 3 - SPRING 4 - UD CLUTCH PISTON5 - SEAL, OUTER 6 - SEAL, INNER 7 - INPUT CLUTCH ASSEMBLY 21s - 120 40TE AUTOMAT

Page 1982 of 2585

CHRYSLER VOYAGER 2004 Service Manual (10) Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig. 226). (11) Install the UD clutch flat snap ring (Fig. 227). (12) Install the last UD clutch disc (Fig. 228). (

Page 1983 of 2585

CHRYSLER VOYAGER 2004 Service Manual (14) Seat tapered snap ring to ensure proper installation (Fig. 231) (Fig. 232). Fig. 231 Seating Tapered Snap Ring 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 - SCREWDRIVER F

Page 1984 of 2585

CHRYSLER VOYAGER 2004 Service Manual (15) Install input clutch assembly to the Input Clutch Pressure Fixture±Tool 8391 (Fig. 233). (16) Set up dial indicator on the UD clutch pack as shown in (Fig. 234). (17) Using moderate pressure, pr
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