Chrysler Town, Dodge Caravan. Manual — part 32
DIAGNOSIS AND TESTING - REAR DRIVELINE
MODULE OPERATION
Driveline
module
operation
requires
relatively
straight-forward diagnosis. Refer to the following
chart:
DRIVELINE MODULE DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSES
CORRECTION
Rear wheels not
overrunning
1) Bi-directional overrunning clutch
failure
1) Replace overrunning clutch
components as required
No AWD in forward or
reverse directions, propeller
shaft turning
1) Bi-directional overrunning clutch
failure
1) Replace overrunning clutch
components as required
2) Viscous coupling failure
2) Replace viscous coupling
3) Rear differential failure
3) Replace the rear differential
assembly
No AWD in forward or
reverse directions, propeller
shaft not turning
1) Power transfer unit failure.
1) Replace power transfer unit
components as necessary
Vibration at all speeds,
continuous torque transfer
1) Mis-matched tires, worn tires on
front axle.
1) Replace worn or incorrect
(mis-matched) tires with same
make and size
REMOVAL
(1) Raise vehicle on hoist.
(2) Drain fluid from overrunning clutch housing
and/or differential assembly if necessary.
(3) Remove propeller shaft. (Refer to 3 - DIFFER-
ENTIAL
&
DRIVELINE/PROPELLER
SHAFT
-
REMOVAL)
(4) Disconnect left and right rear halfshafts from
output flanges (Fig. 2).
(5) Remove torque arm mount to body bolts.
(6) Position transmission jack to driveline module
assembly and secure assembly to jack.
(7) Remove two driveline module-to-body bolts
(Fig. 3).
(8) Lower
driveline
module
from
vehicle
and
remove from jack.
Fig. 2 Half Shaft Mounting Bolts
1 - SHAFT
2 - FLANGE
Fig. 3 Rear Drive Line Module Assembly Mounting
Bolts
1 - DRIVELINE MODULE RETAINING BOLT (2)
2 - RUBBER ISOLATOR
3 - WASHER
3 - 26
REAR DRIVELINE MODULE
RS
REAR DRIVELINE MODULE (Continued)
DISASSEMBLY
WARNING: Differential is only to be serviced as an
assembly, and no disassembly is required.
(1) Remove
six
torque
arm-to-differential
case
bolts and remove torque arm assembly (Fig. 4).
(2) Remove input flange nut and washer using
Tool 6958 and a breaker bar (Fig. 5).
(3) Remove input flange (Fig. 6).
(4) Remove input flange seal from overrunning
clutch housing using suitable screwdriver (Fig. 7).
Fig. 4 Torque Arm Fasteners
1 - TORQUE ARM ASSEMBLY
2 - BOLT (SIX)
Fig. 5 Input Flange Nut
1 - INPUT FLANGE
2 - TOOL 6958
Fig. 6 Input Flange
1 - INPUT FLANGE/SHIELD
Fig. 7 Input Flange Seal Removal
1 - INPUT FLANGE SEAL
2 - SCREWDRIVER
RS
REAR DRIVELINE MODULE
3 - 27
REAR DRIVELINE MODULE (Continued)
(5) Remove four overrunning clutch housing-to-dif-
ferential assembly bolts (Fig. 8) and remove housing.
(6) Remove front bearing snap ring (Fig. 14).
(7) Remove front bearing (Fig. 14).
(8) Remove o-ring and washer from overrunning
clutch assembly (Fig. 14).
(9) Remove overrunning clutch assembly from vis-
cous coupler (Fig. 9).
(10) Remove viscous coupler from differential pin-
ion shaft (Fig. 10).
(11) Remove shim (select) from differential pinion
gear (Fig. 11).
Fig. 8 Overrunning Clutch Housing Bolts
1 - OVERRUNNING CLUTCH HOUSING
2 - BOLT (FOUR)
Fig. 9 Overrunning Clutch
1 - OVERRUNNING CLUTCH
2 - VISCOUS COUPLER
Fig. 10 Viscous Coupler
1 - VISCOUS COUPLER
2 - DIFFERENTIAL PINION
Fig. 11 Shim (Select)
1 - SHIM (SELECT)
2 - DIFFERENTIAL PINION
3 - 28
REAR DRIVELINE MODULE
RS
REAR DRIVELINE MODULE (Continued)
(12) Remove overrunning clutch housing large
o-ring from differential assembly (Fig. 14).
(13) Remove output flanges using suitable screw-
drivers and wood blocks to protect casting (Fig. 12).
(14) Remove output flange seals (Fig. 13).
ASSEMBLY
(1) Install output flange seals using tools C4171
and 8493 (Fig. 15).
(2) Install large overrunning clutch housing o-ring
to differential assembly (Fig. 14).
(3) Install shim to differential pinion shaft (Fig.
16).
Fig. 12 Output Flange Removal
1 - WOOD BLOCK
2 - PRYBAR
3 - OUTPUT SHAFT
4 - PRYBAR
5 - WOOD BLOCK
6 - DIFFERENTIAL CASE
Fig. 13 Output Flange Seal Removal
1 - OUTPUT FLANGE SEAL
2 - SCREWDRIVER
RS
REAR DRIVELINE MODULE
3 - 29
REAR DRIVELINE MODULE (Continued)
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