Chrysler Caravan/Voyager/Town and Country 1996-1999

Drive Pinion

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9



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Fig. Fig. 1: Overrunning clutch case to rear carrier bolts



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Fig. Fig. 2: Separating the housings



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Fig. Fig. 3: Overruning clutch snapring removal



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Fig. Fig. 4: Reinstalling the front carrier cover



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Fig. Fig. 5: Removing the pinion nut



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Fig. Fig. 6: Removing the front carrier cover retaining bolts



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Fig. Fig. 7: Removing the front carrier cover and pinion



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Fig. Fig. 8: Removing the output flange using 2 prybars



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Fig. Fig. 9: Differential side gear bolt tightening sequence

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear driveline module from the vehicle.
  4.  
  5. Remove the overrunning clutch case-to-rear carrier bolts. Separate the overrunning clutch case from the rear carrier.
  6.  
  7. Remove the overrunning clutch outer race snapring and slide the clutch race off of the shaft.
  8.  
  9. Using a spline socket and a wrench, remove the pinion nut.
  10.  
  11. Unfasten the front carrier cover retaining bolts and remove the carrier cover.
  12.  
  13. Place a block of wood under the end of the pinion shaft. Tap the end of the pinion against the wood to remove the spacer from the shaft.
  14.  

To install:
  1. Install the front carrier onto the case and tighten the retaining nuts to 105 inch lbs. (12 Nm).
  2.  
  3. Clean and inspect the seal area, apply a light coat of oil to the drive pinion seal.
  4.  
  5. Install the seal using a seal installer. The seal must be installed with the spring towards the rear of the case.
  6.  
  7. Apply a light coat of oil onto the drive pinion spacer and slide it onto the pinion shaft with the tapered side facing out.
  8.  
  9. Apply a light coat of oil to the overrunning clutch seal and install with a seal installer, the seal must be installed with the spring facing outward.
  10.  
  11. Install the pinion nut and tighten to 150 ft. lbs. (203 Nm).
  12.  
  13. Install the overrunning clutch outer race and snapring.
  14.  
  15. Apply Loctite® sealer to the overrunning clutch sealing surface and install the clutch case to the rear carrier. Tighten to 21 ft. lbs. (28 Nm).
  16.  
  17. Install the rear driveline module into the vehicle. Check and fill the fluid as required.
  18.  

 
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