Chrysler Caravan/Voyager/Town n Country 1984-1995

5-Speed Transaxle Overhaul; Part Two

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Extension Housing

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Extension housing seal removal



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Fig. Fig. 2: Installing extension housing seal



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Fig. Fig. 3: Extension housing bearing cap removal



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Fig. Fig. 4: Extension housing components



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Fig. Fig. 5: Installing extension housing bearing cup

  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

See Figures 6 through 14



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Fig. Fig. 6: Input shaft rear bearing cone removal



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Fig. Fig. 7: Input shaft rear bearing cone installation



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Fig. Fig. 8: Input shaft front bearing cone removal



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Fig. Fig. 9: Installing input shaft front bearing cone



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Fig. Fig. 10: Input shaft rear bearing cone removal



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Fig. Fig. 11: Input shaft rear bearing cup installation



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Fig. Fig. 12: Checking input shaft bearing end-play to determine shim thickness



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Fig. Fig. 13: Checking input shaft bearing turning torque



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Fig. Fig. 14: Input shaft shim selection chart

  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.  
  5. Before pressing in the bearing cup, bolt the support plate onto the retainer plate.
  6.  
  7. With the support plate in place, press the bearing cup into the retainer plate.
  8.  
  9. Press the front and rear bearing cones onto the input shaft using the proper tool.
  10.  

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 (1988-91 models) and install the input shaft in the case. Install the bearing retainer plate with the input shaft rear bearing cup pressed in and the support plate installed. Tighten all bolts and nuts to 21 ft. lbs. (28 Nm).
  2.  
  3. 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.
  4.  
  5. The shim required for proper bearing preload is the total of the gauging shim thickness, plus end-play, plus (constant) preload of 0.002-0.003 in. (0.050-0.076mm). Combine shims, if necessary, to obtain a shim within 0.0016 in. (0.04mm) of the required shim.
  6.  
  7. 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.
  8.  

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. (0.1-0.6 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 Figures 15 through 26



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Fig. Fig. 15: Differential bearing cone removal



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Fig. Fig. 16: Differential bearing cone installation



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Fig. Fig. 17: Removing/installing differential ring gear bolts and ring gear



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Fig. Fig. 18: Removing/installing pinion shaft roll pin



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Fig. Fig. 19: Removing/installing pinion shaft



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Fig. Fig. 20: Removing/installing pinion gears, side gears and thrust washers by rotating pinion gears to opening in differential case



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Fig. Fig. 21: Differential gear components



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Fig. Fig. 22: Checking side gear end-play



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Fig. Fig. 23: Checking the differential bearing end-play to determine shim thickness



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Fig. Fig. 24: Checking the differential bearing turning torque



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Fig. Fig. 25: Differential bearing shim selection chart



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Fig. Fig. 26: 5-speed manual transaxle-component identification

  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. Leave the thrust washer out until after the side gear end-play is adjusted.
  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.  

To install:
  1. Attach special tool L-4410, or equivalent, to a suitable extension handle and press the bearing cone onto the differential case.
  2.  
  3. Refer to the appropriate section to check and adjust the bearing preload, if necessary. Check the side gear end-play and select the proper dimension thrust washer.
  4.  

Side Gear End-Play Adjustment
  1. Once assembled, rotate the gears 2 complete revolutions in both a clockwise and counterclockwise direction.
  2.  
  3. Install special tool C-4996, or equivalent, on the bearing cone and mount a dial indicator so that the stylus of the dial rests on the surface of the tool.
  4.  
  5. Move one of the side gears up and down by hand and record the end-play.
  6.  
  7. Zero the dial and rotate the side gear in 90° increments and repeat Step 3.
  8.  
  9. Use the smallest end-play reading recorded and shim the side gear to within 0.001-0.013 in. (0.025-0.330mm). For shimming, 4 select thrust washer sizes are available: 0.8mm, 0.9mm, 1.0mm, and 1.2mm.
  10.  
  11. Repeat Steps 1 through 4 for the other side gear.
  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 (1988-91 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 it 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. Install the shim(s) selected in Step 8 and press the bearing cup into the differential bearing retainer.
  16.  
  17. Using a 1 / 8 in. (3mm) bead of R.T.V. sealant for gaskets, install the differential bearing retainer and extension housing. Tighten the bolts to 21 ft. lbs. (28 Nm).
  18.  
  19. 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. (1.0-1.6 Nm) for new bearings or a minimum of 6 inch lbs. (0.6 Nm) for used bearings. If the turning torque is too low, install a 0.002 in. (0.05mm) thicker shim.
  20.  
  21. Check the turning torque. Repeat Step 11 until the proper turning torque is obtained.
  22.  

TRANSAXLE ASSEMBLY



  1. Assemble 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. Engage the E-clip on the shaft groove to secure the shaft.
  6.  
  7. Install the shift forks and shift rails onto the intermediate gear shaft assembly.
  8.  
  9. Install the intermediate and input shaft gear sets into the transaxle case and make sure that the gears are in proper mesh. Once the gear sets are in place, rotate the 5th speed shifter to the right and the 1-2 and 3-4 shift forks to the left.
  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 1-2, 3-4 and 5th speed shift fork rails into their respective locating holes.
  14.  
  15. Install and tighten the 1-2 shift fork set screw and 5th speed selector guide pin.
  16.  
  17. 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 plate with the transaxle case and install it. The plate will align with the oil trough and the 5th speed shift rail. Install the intermediate shaft rear bearing snapring once the plate is in place and seated.
  18.  
  19. Install the bearing support plate with the retaining bolts. Tighten the bolts to specification.
  20.  
  21. Install the 5th speed gear onto the input shaft. Install a new gear nut with special holding tool 6252, or equivalent. The holding tool must be used to install the gear nut and the old nut must not be reused. Tighten the nut to 190 ft. lbs. (258 Nm) and remove the holding tool.
  22.  
  23. Install the intermediate shaft 5th speed gear, synchronizer hub and struts using special tool C-4888, or an equivalent gear installer.
  24.  
  25. Position the 5th speed synchronizer sleeve and shift fork over the 5th speed shift rail and install it using the alignment marks for reference. Lock the fork to the rail with the set screw.
  26.  
  27. Install the 5th speed synchronizer strut retainer plate with the snapring.
  28.  
  29. Clean the excess sealant from the end cover and make sure the oil fill plug 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.
  30.  
  31. 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.
  32.  
  33. Apply RTV sealant to the portion of the differential bearing retainer that bolts to the ring gear to form a gasket.
  34.  
  35. Position the differential in the support saddles.
  36.  
  37. Connect the bearing retainer to the differential with the inner bolts and tighten the bolts to specification.
  38.  
  39. Remove the O-ring seal from the extension housing and replace it with a new one. Clean the old sealant from the base of the extension and run a bead of new sealant.
  40.  
  41. Connect the extension to the other side of the differential with the outer bolts. Tighten the bolts to specification.
  42.  
  43. 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.
  44.  
  45. Install the remaining extension and differential bearing retainer (outer) bolts and tighten them to specification.
  46.  
  47. Remove the transaxle from the holding fixture and install it in the vehicle.
  48.  

 
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