Chrysler RG Voyager. Manual — part 998

INPUT SHAFT COVER SEAL

REMOVAL

The power transfer unit input shaft cover seal is

the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.

(1) Remove P.T.U. end cover bolts (Fig. 30).

(2) Gently tap on end cover ears to separate cover

from case (Fig. 31).

(3) Use special tool No. 6514 and remove the dif-

ferential bearing race located in the end cover (Fig.
32). The race must be removed to gain access to the
seal.

(4) Use special tool No. 7794-A to remove seal (Fig.

33).

Fig. 28 Seal Installation

1 - END COVER
2 - SOCKET
3 - HAMMER

Fig. 29 Bolt Tightening Sequence

Fig. 30 P.T.U. End Cover Bolts

1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT

RS

POWER TRANSFER UNIT

21 - 13

HALF SHAFT INNER SEAL (Continued)

INSTALLATION

The power transfer unit input shaft cover seal is

the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.

(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal

(Fig. 34). When installing seal the spring side of the
seal must face toward the special tool.

(3) Reinstall the original bearing race and shim

using special tool No. 6522 (Fig. 35) and (Fig. 36).

CAUTION: The original shim must be installed
behind the bearing cup to maintain proper bearing
preload.

Fig. 31 End Cover Removal

1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT

Fig. 32 Bearing Race Removal

1 - END COVER
2 - SPECIAL TOOL
No. 6514

Fig. 33 Seal Removal

1 - END COVER
2 - SPECIAL TOOL
7794–A
3 - SLIDE HAMMER
4 - SOFT JAW VICE

Fig. 34 Seal Installation

1 - SPECIAL TOOL
No. MD998803
2 - HAMMER
3 - END COVER

21 - 14

POWER TRANSFER UNIT

RS

INPUT SHAFT COVER SEAL (Continued)

(4) Apply Mopar

t Gasket Maker, Loctite Gasket

Eliminator No. 518 or equivalent to sealing surfaces
of end cover.

(5) Place end cover onto P.T.U. case and install

bolts. Tighten bolts to 28 N·m (250 in. lbs.) in the
sequence shown in (Fig. 37). Retighten first bolt after
all others are tight.

CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.

(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.

INPUT SHAFT END SEAL

REMOVAL

The input shaft end seal is located on the end of

the input shaft.

(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 38).

Fig. 35 Bearing Shim and Race

1 - SHIM
2 - BEARING RACE
3 - END COVER

Fig. 36 Installing Bearing Race

1 - HAMMER
2 - END COVER
3 - SPECIAL TOOL
No. 6522
4 - HANDLE
4171

Fig. 37 Bolt Tightening Sequence

Fig. 38 End Cover Bolts

1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT

RS

POWER TRANSFER UNIT

21 - 15

INPUT SHAFT COVER SEAL (Continued)

(3) Tap on end cover ears to separate end cover

from case (Fig. 39).

(4) Pry out seal with a pry bar (Fig. 40).

INSTALLATION

The input shaft end seal is located on the end of

the input shaft.

(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on

soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.

(3) Lubricate seal lip after installing seal into

input shaft.

(4) Clean sealing surfaces of the end cover and

P.T.U. case. Apply a bead of Mopar

t Gasket Maker,

Loctite Gasket Eliminator No. 518 or equivalent.

(5) Place end cover onto P.T.U. case and install

bolts. Tighten bolts to 28 N·m (250 in. lbs.) in the
sequence shown in (Fig. 41). Retighten first bolt after
all others are tight.

CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.

(6) Reinstall P.T.U. assembly.
(7) Check and fill fluids as required.

Fig. 39 Side Cover Removal

1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT

Fig. 40 Seal Removal

1 - POWER TRANSFER UNIT
2 - PRYBAR
3 - SEAL

Fig. 41 Bolt Tightening Sequence

21 - 16

POWER TRANSFER UNIT

RS

INPUT SHAFT END SEAL (Continued)