Chrysler Caravan/Voyager/Town n Country 1984-1995

5-Speed Transaxle Disassembly

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TRANSAXLE DISASSEMBLY



Differential

See Figures 1 through 10



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Fig. Fig. 1: Removing extension housing outer bolts



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Fig. Fig. 2: Removing differential retainer bolts



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Fig. Fig. 3: Removing differential cover bolts



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Fig. Fig. 4: Removing/installing differential cover



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Fig. Fig. 5: Differential cover removed-component identification



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Fig. Fig. 6: Removing/installing extension housing inner bolts



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Fig. Fig. 7: Removing/installing extension housing



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Fig. Fig. 8: Removing/installing differential bearing retainer bolts



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Fig. Fig. 9: Removing/installing differential bearing retainer



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Fig. Fig. 10: Removing/installing differential assembly

  1. Remove the transaxle from the vehicle and position it on suitable holding fixture.
  2.  
  3. Remove the extension outer bolts.
  4.  
  5. Remove the differential retainer outer bolts.
  6.  
  7. Remove the differential assembly.
  8.  

Transaxle

See Figures 11 through 32



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Fig. Fig. 11: Removing/installing selector shaft housing



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Fig. Fig. 12: Select or shaft housing removed-component identification



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Fig. Fig. 13: Removing rear end cover



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Fig. Fig. 14: Fifth speed synchronizer plate and snap ring removal



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Fig. Fig. 15: Removing/installing 5th gear fork set screw



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Fig. Fig. 16: Removing/installing 5th speed synchronizer sleeve and fork



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Fig. Fig. 17: Fifth speed synchronizer removal



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Fig. Fig. 18: Installing 5th speed synchronizer



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Fig. Fig. 19: Removing intermediate shaft 5th speed gear



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Fig. Fig. 20: Removing/installing input shaft 5th gear snapring



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Fig. Fig. 21: Removing input shaft 5th speed gear



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Fig. Fig. 22: Removing/installing bearing support plate bolts



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Fig. Fig. 23: Removing/installing intermediate shaft rear bearing snapring



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Fig. Fig. 24: Removing/installing bearing retainer plate



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Fig. Fig. 25: Removing 5th speed shifter guide pin



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Fig. Fig. 26: Removing/installing 1st/2nd shift fork set screw



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Fig. Fig. 27: Removing shift fork rail



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Fig. Fig. 28: Removing reverse idler gear shaft and gear



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Fig. Fig. 29: Reverse idler gear and plastic stop



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Fig. Fig. 30: Removing gear set from case



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Fig. Fig. 31: Gear set removed from case



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Fig. Fig. 32: Shift forks and rails

  1. Remove the differential cover bolts and gently pry the cover from the extension.
  2.  
  3. Unfasten the extension housing bolts then separate the differential assembly and extension housing. Remove the O-ring seal and clean the RTV from extension housing. Discard the O-ring seal.
  4.  
  5. Unbolt and remove the differential retainer.
  6.  
  7. Unfasten the selector shaft housing assembly bolts and remove the selector shaft housing.
  8.  
  9. Unbolt and remove the rear end cover.
  10.  
  11. Remove the snapring from the 5th speed synchronizer strut retainer plate.
  12.  
  13. Unscrew the 5th speed shift fork set screw. Lift the 5th speed synchronizer sleeve and shift fork off the synchronizer hub. Retrieve the (3) winged struts and top synchronizer spring.
  14.  
  15. Use a puller to remove the 5th speed synchronizer hub. Retrieve the remaining synchronizer spring.
  16.  
  17. Slide the 5th speed gear off the intermediate shaft.
  18.  
  19. Using holding tool 6252, or equivalent, remove the input shaft 5th speed gear nut. This nut is not to be reused.
  20.  
  21. Remove the remaining bearing support plate bolts. Gently pry off the bearing support plate.
  22.  
  23. Remove the large snapring from the intermediate shaft rear ball bearing. Then, gently tap the lower surface of the bearing retainer plate with a plastic hammer to free it and lift it off the transaxle case. Clean the RTV sealer from both surfaces.
  24.  
  25. Unscrew the 5th speed shifter guide pin. Do the same with the 1st/2nd shift fork setscrew. Withdraw the 1st/2nd, 3rd/4th shift fork rail.
  26.  
  27. Slide out the reverse idler gear shaft, gear, and plastic stop.
  28.  
  29. Rotate the 3rd/4th shift fork to the left, and the 5th gear shifter to the right. Pull out the 5th speed shift rail. Pull out the input shaft and intermediate shaft assemblies.
  30.  

 
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