Chrysler RG Voyager. Manual — part 496
(4) Remove propeller shaft assembly (Fig. 10).
(Refer to 3 - DIFFERENTIAL & DRIVELINE/PRO-
PELLER SHAFT - REMOVAL)
(5) Remove cradle plate (Fig. 11).
(6) Remove the Power Transfer Unit mounting
bracket bolts at the rear of the unit (Fig. 12).
(7) Remove the right outboard support bracket and
bolts near the right axle shaft.
(8) Remove the four mounting bolts for the P.T.U.
(Fig. 13)and (Fig. 14).
(9) Remove P.T.U. assembly from vehicle.
INSTALLATION
(1) To install, reverse removal procedure. Check
transaxle fluid and P.T.U. fluid and fill to level.
(2) Refer to the Specifications section for the
proper torque specifications.
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
This procedure is used when the output flange is
replaced. Replacement of the output flange requires
installation of the correct size shim to maintain bear-
ing preload. The shim must protrude from the
new output flange the same distance that the
original
shim
protruded
from
the
original
flange.
(1) Stand the original output flange on end with
shim side pointing up.
(2) Place original shim into groove in top of flange.
(3) Place a straight edge across the shim.
Fig. 10 Driveshaft Flange
1 - DRIVESHAFT FLANGE
Fig. 11 Cradle Plate
1 - CRADLE PLATE
Fig. 12 Remove Rear P.T.U Bracket Bolts
1 - P.T.U. MOUNT BRACKET
2 - P.T.U.
Fig. 13 P.T.U. Lower Mounting Bolts
1 - P.T.U.
2 - P.T.U. MOUNTING BOLTS
21a - 6
POWER TRANSFER UNIT
RG
POWER TRANSFER UNIT (Continued)
(4) Using
feeler
gauge,
measure
the
distance
between the straight edge and the top of the flange
(Fig. 15). Record this measurement.
(5) Repeat steps Step 1 through Step 4using the
new flange and the original shim. Record this
measurement.
(6) If measurements are not equal, use a new shim
that protrudes from new output flange. Make sure it
protrudes the same amount.
(7) For Example: The original shim protrudes
0.075 inch from the original output flange. Place the
original shim into the new output flange. The pro-
trusion of the shim in the new flange is 0.085 inch.
This indicates that a 0.010 inch thinner shim is
required to maintain the original protrusion.
(8) Install output flange and torque flange nut to
244 N·m (180 ft. lbs.).
(9) Check the turning torque of the pinion before
installing the rear cover into the P.T.U. The turning
torque should be between 2.0 N·m and 2.5 N·m (17
in. lbs. and 22 in. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION
. . . . . . . . . . . . . . . . . . . . TORQUE
End Cover . . . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Fill Plug . . . . . . . . . . . . . . . . . 27 N·m (240 in. lbs.)
Flange Nut . . . . . . . . . . . . . . . 162 N·m (120 ft. lbs.)
Inspection Plug . . . . . . . . . . . . 20 N·m (180 in. lbs.)
Rear Cover . . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Ring Gear . . . . . . . . . . . . . . . . . 94 N·m (70 ft. lbs.)
Fig. 14 P.T.U. Upper Mounting Bolts
1 - P.T.U. UPPER MOUNTING BOLTS
2 - P.T.U.
Fig. 15 Output Flange Shim Measurement
1 - MEASURE THIS DIMENSION
2 - SHIM
3 - O-RING
4 - OUTPUT FLANGE
RG
POWER TRANSFER UNIT
21a - 7
POWER TRANSFER UNIT (Continued)
SPECIAL TOOLS
SDP POWER TRANSFER UNIT
5049-a Seal Puller
5065 Bearing Installer
6514 Bearing Remover
6522 Bearing Remover
7794-a Bearing Remover
C-4171 Handle
C-4171-2 Handle
C-4657 Seal Installer
MD998200 Intaller
21a - 8
POWER TRANSFER UNIT
RG
POWER TRANSFER UNIT (Continued)
DIFFERENTIAL CARRIER SEAL
REMOVAL
NOTE: The Power Transfer Unit must be removed
from the vehicle to replace this seal.
(1) Remove PTU from transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL)
(2) Use a pry bar to remove seal from retainer
plate (Fig. 16). Be careful not to damage seal journal
when removing seal.
INSTALLATION
(1) Using a large socket, carefully install new seal.
The spring side of the seal must face the transaxle
differential.
(2) Install the PTU to the transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - INSTALLATION)
(3) Check PTU fluid level. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/POWER TRANSFER UNIT -
STANDARD PROCEDURE)
END COVER BALL BEARING
REMOVAL
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
(1) Raise vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove output seal with a hammer and chisel
(Fig. 17).
(4) Remove bearing retaining snap ring (Fig. 18).
MD998334 Seal Installer
MD998346 Bearing Puller
Fig. 16 Transaxle Differential Carrier Seal
1 - TRANSAXLE CASE
2 - DIFFERENTIAL CARRIER SEAL
3 - RETAINER PLATE
Fig. 17 Output Seal Removal
1 - HAMMER
2 - CHISEL
3 - SEAL
4 - POWER TRANSFER UNIT
RG
POWER TRANSFER UNIT
21a - 9
POWER TRANSFER UNIT (Continued)
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