2004 CHRYSLER VOYAGER Service Manual

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Page 2057 of 2585

CHRYSLER VOYAGER 2004 Service Manual (32) Install the transfer shaft gear using Tool 6261 (Fig. 105). 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 2058 of 2585

CHRYSLER VOYAGER 2004 Service Manual (38) Install low/reverse clutch pack (Fig. 109). Leave uppermost disc out until snap ring is installed. (39) Install low/reverse reaction plate flat snap ring (Fig. 110). (40) Install remaining low/re

Page 2059 of 2585

CHRYSLER VOYAGER 2004 Service Manual (42) Install tapered snap ring (with tapered side up) as shown in (Fig. 113) (Fig. 114). (43) Set up dial indicator as shown in (Fig. 115) to measure low/reverse clutch clearance. Press down on clutch

Page 2060 of 2585

CHRYSLER VOYAGER 2004 Service Manual (45) Orient 2/4 clutch return spring to retainer as shown in (Fig. 117), and install to transaxle (Fig. 118). (46) Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (

Page 2061 of 2585

CHRYSLER VOYAGER 2004 Service Manual (49) Install rear sun gear and #7 needle bearing (Fig. 122). NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientat

Page 2062 of 2585

CHRYSLER VOYAGER 2004 Service Manual (52)DETERMINING #4 THRUST PLATE THICKNESS / INPUT SHAFT END PLAY: (a) Select the thinnest #4 thrust plate thickness and install to input clutch assembly (Fig. 125). Use petrolatum to retain. (b) Insta

Page 2063 of 2585

CHRYSLER VOYAGER 2004 Service Manual NO. 4 THRUST PLATE CHART PART NUMBER THICKNESS4431665AB 1.60mm (0.063 in.) 3836237AB 1.73mm (0.068 in.) 4431666AB 1.80mm (0.071 in.) 3836238AB 1.96mm (0.077 in.) 4431667AB 2.03mm (0.080 in.) 3836239AB

Page 2064 of 2585

CHRYSLER VOYAGER 2004 Service Manual (57) Install oil pump assembly (Fig. 133). (58) Install oil pump-to-case bolts and torque to 27 N´m (20 ft. lbs.) (Fig. 134). (59) Install low/reverse accumulator (Fig. 135). (60) Install low/reverse
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