Chrysler RG Voyager. Manual — part 995
TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page
page
. . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 21
POWER TRANSFER UNIT
TABLE OF CONTENTS
page
page
POWER TRANSFER UNIT
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - PTU FLUID
CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIFFERENTIAL CARRIER SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
END COVER BALL BEARING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
END COVER SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 11
HALF SHAFT INNER SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . 12
INPUT SHAFT COVER SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 14
INPUT SHAFT END SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . 16
INPUT SHAFT SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 18
OUTER HALF SHAFT SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR COVER O-RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 20
POWER TRANSFER UNIT
DESCRIPTION
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located.
The Power Transfer Unit is sealed from the trans-
axle and has its own oil sump. The Unit uses Mopar
t
SAE 80W-90 Gear and Axle Lubricant (MS-9020) and
holds 1.15 liters (1.22 quarts).
Service of the Power Transfer Unit is limited to:
• Fluid Change
• Seals
• Gaskets
• One ball bearing
• Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
RS
TRANSMISSION/TRANSAXLE
21 - 1
Power
T
ransfer
Unit
Components
21 - 2
POWER TRANSFER UNIT
RS
POWER TRANSFER UNIT (Continued)
OPERATION
The Transfer Unit provides the power to the rear
wheels through a hypoid ring gear and pinion set.
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 1), (Fig. 2), (Fig. 3)
and (Fig. 4) for correct seal name and location.
FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certain
seal leaks. These holes are located on the bottom side
of the assembly (Fig. 5).
If fluid leak is detected from either weep hole, seal
replacement is necessary. Do not attempt to repair
the leak by sealing weep holes, they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 5) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
If fluid is leaking from weep hole B (Fig. 5) the
type of fluid leaking will determine which seal is
1 - PLUG
18 - CASE-PTU
35 - SHIM
2 - WASHER FLAT
19 - PINION-PTU
36 - TAPERED ROLLER BEARING
3 - SEAL RING
20 - O-RING
37 - SHAFT ASSY. FRONT L.H.
4 - SNAP RING
21 - SHIM
38 - SEAL RING
5 - BALL BEARING
22 - TAPERED ROLLER BEARING
39 - OIL WIPER
6 - SEAL RING
23 - COVER-PTU CASE REAR
40 - RETAINER DIFFERENTIAL BEARING
7 - COVER-PTU
CASE END
24 - FLANGE TUBE-PTU-OUTPUT ASSY.
41 - SHAFT DIFFERENTIAL PINION
8 - TAPERED ROLLER BEARING
25 - LOCK NUT-HEX FLANGE
42 - PIN
9 - SEAL RING
26 - O- RING
43 - CASE DIFFERENTIAL
10 - SEAL RING
27 - RETAINER PLATE
44 - TAPERED ROLLER BEARING CONE
11 - HEX HEAD SCREW
28 - O-RING
45 - SEAL RING
12 - SHAFT-PTU INPUT
29 - BRACKET
46 - SEAL RING
13 - GEAR-PTU RING
30 - THRUST WASHER
47 - PLUG
14 - TROUGH-PTU (RT.)
31 - SIDE GEAR-DIFFERENTIAL
48 - O-RING
15 - TROUGH-PTU (LT.)
32 - FINAL DRIVE GEAR
49 - SHIM
16 - TAPERED ROLLER BEARING
33 - PINION DIFFERENTIAL
50 - MAGNET
17 - HEX HEAD SCREW
34 - WASHER DIFFERENTIAL PINION
51 - DOWEL
52 - SHAFT ASSY. FRONT R.H.
53 - HEX HEAD SCREW
Fig. 1 Seal
1 - INPUT SHAFT
2 - P.T.U. CASE
3 - MAGNET
4 - INPUT SHAFT END SEAL
5 - OUTPUT SHAFT
6 - RING GEAR
7 - REAR COVER
Fig. 2 Seal Location
1 - REAR COVER
2 - END COVER
3 - OUTER HALFSHAFT SEAL
4 - P.T.U. CASE
5 - P.T.U. OUTPUT SEAL
RS
POWER TRANSFER UNIT
21 - 3
POWER TRANSFER UNIT (Continued)
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input shaft end seal
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner
seal and P.T.U. input shaft cover seal should be
replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 6).
(3) Fluid level should be within 3/16” from bottom
of inspection hole. Add Mopar
t Gear and Axle Lubri-
Fig. 3 Seal Location
1 - INPUT SHAFT
2 - OUTPUT SHAFT
3 - REAR COVER
4 - P.T.U. CASE
5 - INPUT SHAFT SEAL
Fig. 4 Seal Location
1 - P.T.U. INPUT SHAFT COVER SEAL
2 - HALF SHAFT INNER SEAL
3 - INSIDE VIEW OF P.T.U. END COVER
Fig. 5 Weep Hole Locations
1 - ENGINE OIL PAN
2 - WEEP HOLE “A”
3 - TRANSAXLE CASE
4 - P.T.U.
5 - WEEP HOLE “B”
Fig. 6 Inspection Plug
1 - INSPECTION PLUG
21 - 4
POWER TRANSFER UNIT
RS
POWER TRANSFER UNIT (Continued)
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