Chrysler Caravan/Voyager/Town n Country 1984-1995

5-Speed Transaxle Overhaul; Part One

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Clutch Release Bearing

See Figures 1 and 2



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Fig. Fig. 1: Removing clutch release shaft



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Fig. Fig. 2: Removing clutch release shaft components

  1. Remove the 1st/2nd, 3rd/4th, and 5th speed shift forks.
  2.  
  3. To remove the clutch release bearing, disengage the E-clips from the clutch release shaft, then disassemble the clutch shaft components.
  4.  

Input Shaft Oil Seal

See Figures 3, 4, 5 and 6



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Fig. Fig. 3: Removing input shaft seal retainer



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Fig. Fig. 4: Input shaft seal retainer components



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Fig. Fig. 5: Installing new input shaft seal



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Fig. Fig. 6: Reverse lever components

  1. Remove the input shaft seal retainer bolts, seal, retainer assembly and the select shim.
  2.  

Reverse Shift Lever
  1. Remove the reverse shift lever E-clip and flat washer and disassemble the reverse shift lever components.
  2.  

SUBASSEMBLY



See Figures 7, 8 and 9

Transaxle Case


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Fig. Fig. 7: Removing bearing retainer strap



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Fig. Fig. 8: Removing or installing intermediate shaft front bearing



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Fig. Fig. 9: Front bearing and oil feeder assembly

  1. Press the input shaft front bearing cup from the transaxle case.
  2.  
  3. Unbolt and remove the intermediate shaft front bearing retaining strap.
  4.  
  5. Remove the intermediate shaft front bearing and oil feeder using a bearing puller.
  6.  

To assemble:
  1. Press the intermediate shaft front bearing with the oil feeder into the transaxle case. The bearing identification letters must be facing upward during installation.
  2.  
  3. Install the intermediate shaft front bearing retaining strap.
  4.  
  5. Press the input shaft front bearing cup into the transaxle case.
  6.  

Intermediate Shaft Assembly

See Figures 10 through 26



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Fig. Fig. 10: Removing/installing intermediate shaft bearing snapring



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Fig. Fig. 11: Intermediate shaft bearing removal



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Fig. Fig. 12: Installing intermediate shaft rear bearing



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Fig. Fig. 13: Removing 3rd/4th synchronizer hub snapring



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Fig. Fig. 14: 3rd/4th synchronizer hub and 3rd speed gear removal



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Fig. Fig. 15: Installing 3rd/4th synchronizer hub and gear



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Fig. Fig. 16: Snapring and split thrust washer removal



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Fig. Fig. 17: Split thrust washer installation position



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Fig. Fig. 18: Removing 2nd speed gear and stop ring



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Fig. Fig. 19: Removing 1st/2nd synchronizer assembly



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Fig. Fig. 20: Removing 1st/2nd synchronizer hub snapring



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Fig. Fig. 21: Removing 1st speed gear and 1st/2nd synchronizer



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Fig. Fig. 22: Removing st speed gear thrust washer



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Fig. Fig. 23: Intermediate shaft-exploded view



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Fig. Fig. 24: 1st/2nd and 3rd/4th synchronizer-exploded view



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Fig. Fig. 25: 5th speed synchronizer assembly-exploded view



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Fig. Fig. 26: Synchronizer sleeves-identification

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.  
  9. Remove the 2nd speed gear from the intermediate shaft and disengage the 1-2 synchronizer hub snapring.
  10.  
  11. Pull the 1st speed gear and 1-2 synchronizer assembly from the intermediate shaft.
  12.  

The 1-2 synchronizer assembly components are not interchangeable with other synchronizers.

To assemble:

  1. Install the 1st speed gear thrust washer, 1st speed 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. Engage 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 0.003 in. (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 he matchmarks are aligned.

Selector Shaft Housing

See Figures 27, 28, 29, 30 and 31



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Fig. Fig. 27: Removing selector shaft snapring and boot



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Fig. Fig. 28: Removing selector shaft seal



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Fig. Fig. 29: Removing/installing selector shaft E-clip



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Fig. Fig. 30: Selector shaft housing components



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Fig. Fig. 31: Removing/installing selector shaft

  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 5th speed load spring and push the E-clip from the selector shaft. Disengage 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

See Figures 32, 33, 34, 35 and 36



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Fig. Fig. 32: Differential bearing retainer seal removal



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Fig. Fig. 33: Installing differential bearing retainer seal



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Fig. Fig. 34: Removing/installing differential bearing retainer



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Fig. Fig. 35: Differential bearing retainer assembly



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Fig. Fig. 36: Inserting shim and differential bearing cup

  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.  

 
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