Chrysler RG Voyager. Manual — part 495
Power
T
ransfer
Unit
Components
21a - 2
POWER TRANSFER UNIT
RG
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
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POWER TRANSFER UNIT
21a - 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).
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
21a - 4
POWER TRANSFER UNIT
RG
POWER TRANSFER UNIT (Continued)
(3) Fluid level should be within 3/16” from bottom
of inspection hole. Add Mopar
t Gear and Axle Lubri-
cant 80W-90 as necessary with suitable suction gun
(Fig. 7).
(4) Install inspection plug and torque to 20 N·m
(180 in. lbs.) torque.
(5) Lower vehicle.
STANDARD PROCEDURE - PTU FLUID CHANGE
NOTE: PTU Fluid should be changed upon servic-
ing the unit, or at the unit’s regular scheduled inter-
val. (Refer to LUBRICATION & MAINTENANCE/
MAINTENANCE SCHEDULES - DESCRIPTION)
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 8).
(3) Using suitable suction gun, draw fluid from
PTU. Make sure hose contacts bottom of case to
ensure all fluid is removed.
(4) Add 1.15 liters (1.22 quarts) of Mopar
t Gear
and Axle Lubricant 80W-90 with suction gun (Fig. 9).
(5) Install inspection plug and torque to 20 N·m
(180 in. lbs.) torque.
(6) Lower vehicle.
REMOVAL
(1) Raise vehicle and remove front wheels.
CAUTION: A certain amount of oil will drain out of
the transaxle when the drive shaft is removed.
(2) Remove right front drive shaft. Install a plug
into the right driveshaft seal hole. (Refer to 3 - DIF-
FERENTIAL
&
DRIVELINE/HALF
SHAFT
-
REMOVAL)
(3) Mark propeller shaft front flange.
CAUTION: Do not let propeller shaft to hang freely.
Damage to the shaft will occur.
Fig. 7 Removing/Adding PTU Fluid
1 - SUCTION GUN
2 - INSPECTION HOLE
Fig. 8 Inspection Plug
1 - INSPECTION PLUG
Fig. 9 Adding Fluid to PTU
1 - SUCTION GUN
2 - INSPECTION HOLE
RG
POWER TRANSFER UNIT
21a - 5
POWER TRANSFER UNIT (Continued)
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