2005 CHRYSLER CARAVAN Service Manual

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Page 1625 of 2339

CHRYSLER CARAVAN 2005 Service Manual NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replace- ment requires replacement of the piston assembly. (27) Remove 2/4 clutch retainer (Fig. 42). (28) Rem

Page 1626 of 2339

CHRYSLER CARAVAN 2005 Service Manual (31) Remove low/reverse reaction plate (Fig. 46). (32) Remove one low/reverse clutch disc (Fig. 47).(33) Remove low/reverse reaction plate snap ring (Fig. 48). (34) Remove low/reverse clutch pack (Fig

Page 1627 of 2339

CHRYSLER CARAVAN 2005 Service Manual (35) Remove transfer gear cover-to-case bolts (Fig. 50). (36) Remove transfer gear cover (Fig. 51).(37) Using Tool 6259, remove transfer shaft gear- to-shaft nut and coned washer (Fig. 52) (Fig. 53).

Page 1628 of 2339

CHRYSLER CARAVAN 2005 Service Manual (38) Using tool L-4407A, remove transfer shaft gear (Fig. 54). (39) Remove transfer gear shim (select) (Fig. 55).(40) Remove bearing cup retainer (Fig. 56). (41) Remove transfer gear bearing cone usin

Page 1629 of 2339

CHRYSLER CARAVAN 2005 Service Manual (42) Remove transfer shaft bearing cup from retainer using Tool 6062 (Fig. 58). (43) Using Tool 6051, remove transfer shaft bear- ing snap ring (Fig. 59).(44) Using tool 5049A, remove transfer shaft f

Page 1630 of 2339

CHRYSLER CARAVAN 2005 Service Manual (46) Using tool P-334, press transfer shaft bearing cone off of shaft (Fig. 62). (47) Bend output gear retaining strap ears flat to allow bolt removal. (48) Remove output shaft stirrup strap bolts (Fi

Page 1631 of 2339

CHRYSLER CARAVAN 2005 Service Manual (51) Using Tool L4407A, and button 6055, remove output gear from shaft (Fig. 67).(52) Remove output gear bearing shim (select) (Fig. 68). (53) Using setup as shown in (Fig. 69), remove output gear bea

Page 1632 of 2339

CHRYSLER CARAVAN 2005 Service Manual (54) Remove rear carrier assembly from transaxle (Fig. 70). (55) Remove rear carrier assembly bearing cone using setup shown in (Fig. 71).(56) Install low/reverse spring compressor tool as shown in (F
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