2005 CHRYSLER CARAVAN Service Manual

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Page 1489 of 2339

CHRYSLER CARAVAN 2005 Service Manual NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly. (62) Remove low/reverse clutch piston (Fig. 7

Page 1490 of 2339

CHRYSLER CARAVAN 2005 Service Manual (66) Using a hammer and suitable drift, drive out inner output bearing cup (Fig. 83). (67) Using tool 6062, remove outer output bearing cup (Fig. 84). ASSEMBLY CAUTION: The cooler bypass valve must be

Page 1491 of 2339

CHRYSLER CARAVAN 2005 Service Manual (3) Install low/reverse piston retainer (Fig. 87). (4) Install low/reverse piston retainer-to-case bolts (Fig. 88) and torque to 5 N´m (45 in. lbs.). NOTE: The Low/Reverse Clutch Piston has bonded se

Page 1492 of 2339

CHRYSLER CARAVAN 2005 Service Manual (7) Install guide bracket into position and insert pivot shaft (Fig. 92).(8) Install anchor shaft and plug (Fig. 93). Make sure guide bracket and split sleeve are in contact with the rear of the trans

Page 1493 of 2339

CHRYSLER CARAVAN 2005 Service Manual (10) Install low/reverse spring compressor into position (Fig. 95). Compress low/reverse piston and install snap ring as shown in (Fig. 96).(11) Install rear carrier bearing cone using Tool 6053 (Fig.

Page 1494 of 2339

CHRYSLER CARAVAN 2005 Service Manual (13) Install output gear bearing cone using Tool 5052 (Fig. 99). (14)OUTPUT GEAR BEARING ADJUST- MENT: (a) With output gear Installd, install a 4.50 mm (0.177 in.) gauging shim (Fig. 101) on the rear

Page 1495 of 2339

CHRYSLER CARAVAN 2005 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.)4412830AB0.53mm (0.021 in.)3.94mm (0.155 in.)4412818AB 0.08mm (0.00

Page 1496 of 2339

CHRYSLER CARAVAN 2005 Service Manual (15) Install the output gear and bearing assembly using Tool 6261 (Fig. 102). (16) Install NEW output gear retaining bolt and washer (Fig. 103). Using Tool 6259, torque output gear retaining bolt to 2
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