2004 CHRYSLER VOYAGER Service Manual

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Page 2033 of 2585

CHRYSLER VOYAGER 2004 Service Manual (22) Remove #4 thrust plate (Fig. 22). (23) Remove front sun gear assembly and #4 thrust washer (Fig. 23). (24) Remove front carrier/rear annulus assembly and #6 needle bearing (Fig. 24). (25) Remove

Page 2034 of 2585

CHRYSLER VOYAGER 2004 Service Manual (26) Setup tool 5058 as shown in (Fig. 27). Com- press 2/4 clutch return spring (just enough to remove snap ring) and remove snap ring. NOTE: Verify that Tool 5058 is centered properly over the 2/4 cl

Page 2035 of 2585

CHRYSLER VOYAGER 2004 Service Manual (29) Remove 2/4 clutch pack (Fig. 30).Tag 2/4 clutch pack for reassembly identification. (30) Remove tapered snap ring (Fig. 31). (31) Remove low/reverse reaction plate (Fig. 32). (32) Remove one low/

Page 2036 of 2585

CHRYSLER VOYAGER 2004 Service Manual (33) Remove low/reverse reaction plate snap ring (Fig. 34). (34) Remove low/reverse clutch pack (Fig. 35). (35) Remove transfer gear cover-to-case bolts (Fig. 36). (36) Remove transfer gear cover (Fig

Page 2037 of 2585

CHRYSLER VOYAGER 2004 Service Manual (37) Using Tool 6259, remove transfer shaft gear- to-shaft nut and coned washer (Fig. 38) (Fig. 39). (38) Using tool L-4407A, remove transfer shaft gear (Fig. 40). (39) Remove transfer gear shim (sele

Page 2038 of 2585

CHRYSLER VOYAGER 2004 Service Manual (40) Remove bearing cup retainer (Fig. 42). (41) Remove transfer gear bearing cone using setup shown in (Fig. 43). (42) Remove transfer shaft bearing cup from retainer using Tool 6062 (Fig. 44). (43)

Page 2039 of 2585

CHRYSLER VOYAGER 2004 Service Manual (44) Using tool 5049A, remove transfer shaft from transaxle (Fig. 46). (45) Slip bearing cup retainer and oil baffle off of shaft (Fig. 47). (46) Using tool P-334, press transfer shaft bearing cone of

Page 2040 of 2585

CHRYSLER VOYAGER 2004 Service Manual (49) Remove stirrup and strap (Fig. 50). (50) Using Tool 6259 (Fig. 51), remove output shaft gear-to-shaft bolt and washer (Fig. 52). (51) Using Tool L4407A, and button 6055, remove output gear from s
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