Chrysler Caravan/Voyager/Town n Country 1984-1995

4-Speed Transaxle Overhaul

Print

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: 4-speed manual transaxle component identification

TRANSAXLE CASE DISASSEMBLY



See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: 4-speed manual transaxle case components

  1. Remove the transaxle from the vehicle and position it on suitable holding fixture.
  2.  
  3. Unfasten the differential cover bolts and the stud nuts, then remove the cover.
  4.  
  5. Remove the differential bearing retainer bolts.
  6.  
  7. Using tool No. L-4435, or equivalent, rotate the differential bearing retainer to remove it.
  8.  
  9. Remove the extension housing bolts, differential assembly and extension housing.
  10.  
  11. Unbolt and remove the selector shaft housing.
  12.  
  13. Remove the stud nuts and the bolts from the rear end cover then pry off the rear end cover.
  14.  
  15. Remove the large snapring from the intermediate shaft rear ball bearing.
  16.  
  17. Remove the bearing retainer plate by tapping it with a plastic hammer.
  18.  
  19. Remove the 3rd/4th shift fork rail.
  20.  
  21. Remove the reverse idler gear shaft and gear.
  22.  
  23. Remove the input shaft gear assembly and the intermediate shaft gear assembly.
  24.  
  25. To remove the clutch release bearing, disengage the E-clips from the clutch release shaft, then disassemble the clutch shaft components.
  26.  
  27. Remove the input shaft seal retainer bolts, seal, retainer assembly and the select shim.
  28.  
  29. Remove the reverse shift lever E-clip and flat washer and disassemble the reverse shift lever components.
  30.  
  31. Press the input shaft front bearing cup from the transaxle case.
  32.  
  33. Unbolt and remove the intermediate shaft front bearing retaining strap.
  34.  
  35. Remove the intermediate shaft front bearing and oil feeder using a bearing puller.
  36.  
  37. Press the intermediate shaft front bearing with the oil feeder into the transaxle case. The bearing identification letters must be facing upward during installation.
  38.  
  39. Install the intermediate shaft front bearing retaining strap.
  40.  
  41. Press the input shaft front bearing cup into the transaxle case.
  42.  

INTERMEDIATE SHAFT



See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: 4-speed manual transaxle gear train

The 1st/2nd, the 3rd/4th shift forks are interchangeable, however, the synchronizer stop rings are not. The 1st and 2nd synchronizer stop rings have a larger diameter than the other stop rings.

  1. Remove the intermediate shaft rear bearing snapring.
  2.  
  3. Remove the intermediate shaft rear bearing with a bearing puller.
  4.  
  5. Remove the 3rd/4th synchronizer hub snapring.
  6.  
  7. Matchmark then remove the 3rd/4th synchronizer hub and the 3rd speed gear using a puller.
  8.  

To install:
  1. Install the 1st speed gear thrust washer, gear, stop ring and 1-2 synchronizer assembly
  2.  
  3. Install the 1-2 synchronizer snapring.
  4.  
  5. Install the 2nd speed gear and stop ring.
  6.  
  7. Install the retaining ring and split thrust washer. Install the 3rd speed gear and the 3-4 synchronizer. Install the hub snapring.
  8.  
  9. Install the intermediate shaft rear bearing and retaining snapring.
  10.  
  11. Install the intermediate shaft front bearing.
  12.  

Pay attention to the following when servicing the intermediate shaft: when assembling the intermediate shaft, make sure the speed gears turn freely and have a minimum of 0.076mm end-play. When installing the 1st speed gear thrust washer make sure the chamfered edge is facing the pinion gear. When installing the 1st/2nd synchronizer make sure the relief faces the 2nd speed gear. Use an arbor press to install the intermediate shaft rear bearing, the 3rd/4th synchronizer hub and the 3rd speed gear. When installing the 3-4 synchronizer hub and 3rd speed gear, index the snapring 90° to the split washer. During the installation of synchronizer ring assemblies, make sure that all the matchmarks are aligned.

SELECTOR SHAFT HOUSING



  1. Disengage the snapring from the selector shaft boot and remove the boot.
  2.  
  3. Pry the shaft oil seal from the selector shaft housing.
  4.  
  5. With a small prybar positioned against the gearshift selector, compress the crossover and push the E-clip from the selector shaft. Remove the E-clip to release the selector shaft.
  6.  
  7. Withdraw the selector shaft from the selector housing.
  8.  
  9. Unfasten the plate stop retaining bolts and remove the stop.
  10.  
  11. Disassemble the selector shaft housing components.
  12.  

To assemble:
  1. Assemble the selector shaft housing components in the reverse order of removal. Use a new back-up lamp switch gasket if needed.
  2.  
  3. Install the plate stop with the retaining bolts.
  4.  
  5. Insert the selector shaft into the housing.
  6.  
  7. Compress the gearshift selector and install the E-clip.
  8.  
  9. Clean the bore and drive a new oil seal into the housing using the proper tool.
  10.  
  11. Place the boot onto the shaft and retain with the snapring.
  12.  

DIFFERENTIAL BEARING RETAINER



  1. Pry the oil seal from the retainer.
  2.  
  3. Remove the retainer cup with a puller. Be careful not to damage the oil baffle and the select shim .
  4.  
  5. Remove the oil baffle and the select shim from the retainer cup.
  6.  

To assemble:
  1. Drive the oil baffle and select shim into the retainer cup using the proper tool.
  2.  
  3. Drive the retainer cup into the retainer using the proper tool.
  4.  
  5. Drive in a new retainer oil seal.
  6.  

EXTENSION HOUSING



  1. Pry the oil seal from the extension housing.
  2.  
  3. Pull the extension cup from the extension housing using the proper tool.
  4.  
  5. Remove the O-ring and oil baffle from the housing.
  6.  

To assemble:
  1. Install a new O-ring into the groove on the outside of the housing.
  2.  
  3. Press the oil baffle in the housing using the proper tool.
  4.  
  5. Press the bearing cup into the extension housing using the proper tool.
  6.  
  7. Install a new housing oil seal.
  8.  

INPUT SHAFT



  1. Remove the input shaft rear and front bearing cones using a suitable puller.
  2.  
  3. Mount the bearing retainer plate on wood blocks and press the input shaft rear bearing cup from the plate.
  4.  

To install:
  1. Before pressing in the bearing cup, bolt the support plate onto the retainer plate.
  2.  
  3. With the support plate in place, press the bearing cup into the retainer plate.
  4.  
  5. Press the front and rear bearing cones onto the input shaft using the proper tool.
  6.  

Bearing End-Play Adjustment

Shim thickness calculation and end-play adjustment need only be done if any of the following parts are replaced: transaxle case, input shaft seal retainer, bearing retainer plate, rear end cover, input shaft or input shaft bearings.

If any of the above components were replaced, use the following procedure to adjust the bearing preload and proper bearing turning torque.

  1. Select a gauging shim which will give 0.001-0.010 in. (0.025-0.250mm) of end-play.
  2.  

Measure the original shim from the input shaft seal retainer and select a shim 0.010 in. (0.25mm) thinner than the original for the gauging shim.

  1. Install the gauging shim on the bearing cup and the input shaft seal retainer.
  2.  
  3. Alternately tighten the input shaft seal retainer bolts until the retainer is bottomed against the case. Tighten the bolts to 21 ft. lbs. (28 Nm).
  4.  

The input shaft seal retainer is used to draw the input shaft front bearing cup the proper distance into the case bore.

  1. Oil the input shaft bearings with A.T.F. (1984-87 models) or SAE 5W-30 engine oil (1988 models) and install the input shaft in the case.
  2.  
  3. Install the bearing retainer plate with the input shaft rear bearing cup pressed in and the end cover installed. Tighten all bolts and nuts to 21 ft. lbs. (28 Nm).
  4.  
  5. Position the dial indicator to check the input shaft end-play. Apply moderate load, by hand, to the input shaft splines. Push toward the rear while rotating the input shaft back and forth a number of times and to settle out the bearings. Zero the dial indicator. Pull the input shaft toward the front while rotating the input shaft back and forth a number of times to settle out the bearings. Record the end-play.
  6.  
  7. The shim required for proper bearing preload is the total of the gauging shim thickness, plus end-play, plus (constant) preload of 0.0019-0.0029 in. (0.050-0.076mm). Combine shims if necessary, to obtain a shim within 0.0016 in. (0.04mm) of the required shim.
  8.  
  9. Remove the input shaft seal retainer and gauging shim. Install the shim(s) selected in Step 6 and install the input shaft seal retainer with a 1 / 8 in. (3mm) bead of RTV sealant.
  10.  

Keep RTV sealant out of the oil slot.

  1. Tighten the input shaft seal retainer bolts to 21 ft. lbs. (28 Nm).
  2.  

The input shaft seal retainer is used to draw the input shaft front bearing cup the proper distance into the case bore.

  1. Using special tool L-4508, or equivalent, and an inch lb. torque wrench, check the input shaft turning torque. The turning torque should be 1-5 inch lbs. (0.1-0.5 Nm) for new bearings or a minimum of 1 inch lb. (0.1 Nm) for used bearings. If the turning torque is too high, install a 0.0016 in. (0.04mm) thinner shim. If the turning torque is too low, install a 0.0016 in. (0.04mm) thicker shim.
  2.  
  3. Check the input shaft turning torque. Repeat Step 9 until the proper bearing turning torque is obtained.
  4.  

DIFFERENTIAL



See Figure 4



Click image to see an enlarged view

Fig. Fig. 4: 4-speed manual transaxle differential

  1. Remove the bearing cone from the differential case.
  2.  
  3. Remove the ring gear bolts and separate the gear from the differential case. The ring gear bolts are epoxy patch type bolts and not to be reused.
  4.  
  5. Using a steel punch and hammer, knock the pinion shaft split pin from the ring gear and differential case.
  6.  
  7. Withdraw the pinion shaft(s) from the differential case.
  8.  
  9. Rotate the side gears to align them with the case opening and remove the thrust washers, side gears and pinion gears.
  10.  

Shim thickness calculation and bearing preload adjustment need only be done if any of the following parts are replaced: transaxle case, input shaft seal retainer, bearing retainer plate, rear end cover, input shaft or input shaft bearings. If any of the those components were replaced, refer to the appropriate section to adjust the bearing preload, proper bearing turning torque or side gear end-play.

  1. In their original order, install the side gears, pinion gears and pinion gear washers.
  2.  
  3. Insert the pinion shaft(s) into the differential case making sure that the hole in the shaft is aligned with the roll pin opening in the case.
  4.  
  5. Insert the pinion shaft roll pin(s) into the notched opening(s) on the side of the differential case and drive them into place.
  6.  
  7. Connect the ring gear to the differential case using new bolts. Tighten the bolts in a crisscross pattern to the proper specification.
  8.  
  9. Attach special tool L-4410, or equivalent, to a suitable extension handle and press the bearing cone onto the differential case.
  10.  
  11. Refer to the appropriate section to check and adjust the bearing preload, if necessary.
  12.  

Bearing Preload Adjustment Procedure
  1. Remove the bearing cup and existing shim from the differential bearing retainer.
  2.  
  3. Select a gauging shim which will give 0.001-0.010 in. (0.025-0.250mm) end-play.
  4.  

Measure the original shim from the differential bearing retainer and select a shim 0.015 in. (0.38mm) thinner than the original for the gauging shim.

  1. Install the gauging shim in the differential bearing retainer and press in the bearing cup. Installation of the oil baffle is not necessary when checking differential assembly end-play.
  2.  
  3. Lubricate the differential bearings with A.T.F. (1984-87 models) or SAE 5W-30 engine oil (1988-89 models) and install the differential assembly in the transaxle case.
  4.  
  5. Inspect the extension housing for damage and replace it as necessary.
  6.  
  7. Position the transaxle with the bell housing facing down on the workbench and secure with C-clamps. Position the dial indicator.
  8.  
  9. Apply a medium load to the ring gear, by hand, in the downward direction while rolling the differential assembly back and forth a number of times to settle the bearings. Zero the dial indicator. To obtain end-play readings, apply a medium load upward by hand while rolling the differential assembly back and forth a number of times to settle out the bearings. Record the end-play.
  10.  
  11. The shim required for proper bearing preload is the total of the gauging shim thickness, plus end-play, plus (constant) preload of 0.010 in. (0.25mm). Combine shims if necessary, to obtain a shim within 0.002 in. (0.05mm) of the shim(s).
  12.  
  13. Remove the differential bearing retainer.
  14.  
  15. Remove the bearing cup and gauging shim. Properly install the oil baffle making sure the oil baffle is not damaged.
  16.  
  17. Install the shim(s) selected in Step 8 and press the bearing cup into the differential bearing retainer.
  18.  
  19. Using a 1 / 8 in. (3mm) bead of RTV sealant for gaskets, install the differential bearing retainer and extension housing. Tighten the bolts to 21 ft. lbs. (28 Nm).
  20.  
  21. Using an appropriate tool and an inch lb. torque wrench, check the turning torque of the differential assembly. The turning torque should be 9-14 inch lbs. (1.0-1.5 Nm) for new bearings or a minimum of 6 inch lbs. (0.7 Nm) for used bearings. If the turning torque is too low, install a 0.002 in. (0.05mm) thicker shim.
  22.  
  23. Check the turning torque. Repeat Step 11 until the proper turning torque is obtained.
  24.  

TRANSAXLE CASE ASSEMBLY



  1. Engage the reverse shift lever components to the transaxle case and lock it in place with the E-clip.
  2.  
  3. Clean the input shaft bore and press in a new oil seal with special tool C-4674, or equivalent. Place the select shim into the retainer race and bolt the input shaft seal retainer onto the transaxle case. The drain hole on the retainer sleeve must be facing downward.
  4.  
  5. Assemble the clutch release shaft components in the reverse order of disassembly and secure the release lever with the E-clip. Insert the release shaft spline end through the bushing and engage it with the release shaft fork. Install the E-clip on the shaft groove to secure the shaft.
  6.  
  7. Install the shift fork and shift fork pads onto the intermediate shaft gear set.
  8.  
  9. Install the intermediate and input shaft gear sets.
  10.  
  11. Install the reverse idler gear (with plastic stop) so that the roll pin on the end of the gear shaft aligns with the roll pin notch in the transaxle case. Lock the gear and engage the reverse shift lever. Make sure the plastic stop is firmly seated on the gear.
  12.  
  13. Install the 3-4 shift fork rail into the locating hole above the intermediate shaft assembly.
  14.  
  15. Remove all the excess sealant from the bearing retainer plate and run an 1 / 8 in. (3mm) bead of RTV around the plate's seating surface. Keep the RTV away from the bolt holes. Align the locating dowel on the plate with the dowel on the transaxle case and install by tapping the plate with a rubber mallet. Install the intermediate shaft rear bearing snapring once the plate is in place.
  16.  
  17. Clean the excess sealant from the end cover and make sure the oil feeder hole is clear. Run a bead of RTV around the cover's seating surface and place the cover on the bearing retainer plate. Install the end cover bolts and tighten to specification.
  18.  
  19. Clean the excess sealant from the selector shaft housing. If the back-up light switch was removed, install the switch with a new gasket. Run a 1 / 8 in. (3mm) bead of RTV sealant around the cover's seating surface and install the housing with the housing bolts. Tighten the bolts to specification.
  20.  
  21. Connect the differential to the extension housing. Use a new extension housing O-ring seal. Attach the housing with the housing bolts and tighten the bolts to specification.
  22.  
  23. Seal the differential bearing retainer with RTV and tighten the retainer with special tool L-4435, or equivalent spanner wrench.
  24.  
  25. Install the differential bearing retainer bolts and tighten them to specification.
  26.  
  27. If the magnet was removed from the differential cover, install it at this time. Clean the excess sealant from the differential cover and run a 1 / 8 in. (3mm) bead of RTV around the cover's seating surface. Install the differential cover with the cover bolts. Tighten the bolts to specification.
  28.  
  29. Remove the transaxle from the holding fixture and install it in the vehicle.
  30.  

 
label.common.footer.alt.autozoneLogo