2004 CHRYSLER VOYAGER Service Manual

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Page 2049 of 2585

CHRYSLER VOYAGER 2004 Service Manual (14)OUTPUT GEAR BEARING ADJUST-
MENT: (a) With output gear removed, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 87) on the rear car-
rier assembly hub, using grease to hold the shim in
place. (b)

Page 2050 of 2585

CHRYSLER VOYAGER 2004 Service Manual OUTPUT GEAR BEARING SHIM CHART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm (0.002 in.) 4.42mm (0.174
in.) 4412830AB 0.53mm
(0.021 in.) 3.94mm (0.155
in.) 4412818AB
0.08mm

Page 2051 of 2585

CHRYSLER VOYAGER 2004 Service Manual (15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 88).
(16) Install NEW output gear retaining bolt and
washer (Fig. 89). Using Tool 6259, torque output gear
retaining bolt to 271

Page 2052 of 2585

CHRYSLER VOYAGER 2004 Service Manual (18) Install output gear stirrup with serrated side
out (Fig. 92).
(19) Install retaining strap.
(20) Install strap bolts but do not tighten at this
time (Fig. 93). (21) Rotate stirrup clockwise again

Page 2053 of 2585

CHRYSLER VOYAGER 2004 Service Manual (23) Bend tabs on strap up against flats of bolts
(Fig. 96).
(24) Install transfer shaft bearing cone using Tool
6052 (Fig. 97). (25) Install bearing cup and oil baffle to transfer
shaft (Fig. 98).
(2

Page 2054 of 2585

CHRYSLER VOYAGER 2004 Service Manual (27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 100).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 101). (29) Install bearing cup retainer to transa

Page 2055 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. 104). (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. 104). (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. 104) 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. 104 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
21s - 194 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

Page 2056 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.)

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