Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 63
TRANSAXLE
CONTENTS
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A-523 MANUAL TRANSAXLE
. . . . . . . . . . . . . . . 1
ALL WHEEL DRIVE POWER TRANSFER UNIT
(P.T.U.)
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4-SPEED ELECTRONIC TRANSAXLE HYDRAULIC
SCHEMATICS
. . . . . . . . . . . . . . . . . . . . . . . . 184
4-SPEED ELECTRONIC TRANSAXLE ON-BOARD
DIAGNOSTICS
. . . . . . . . . . . . . . . . . . . . . . . 157
4-SPEED ELECTRONIC AUTOMATIC
TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . 82
SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . 197
THREE SPEED TORQUEFLITE AUTOMATIC
TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . 32
THREE SPEED TRANSAXLE HYDRAULIC
SCHEMATICS
. . . . . . . . . . . . . . . . . . . . . . . . 176
A-523 MANUAL TRANSAXLE
INDEX
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page
Bearing Adjustment Procedure
. . . . . . . . . . . . . . . 29
Differential Bearing Preload Adjustment
. . . . . . . . 30
Gearshift Linkage Adjustment (Cable Operated)
. . . 2
General Information
. . . . . . . . . . . . . . . . . . . . . . . . 1
Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
In-Car Transaxle Disassemble/Assemble
. . . . . . . . 4
Out of Car Transaxle—Disassemble and Assemble
. 5
Subassembly-Recondition
. . . . . . . . . . . . . . . . . . 15
Transaxle Removal and Installation
. . . . . . . . . . . . 4
GENERAL INFORMATION
Safety goggles should be worn at all times
when working on these transaxles. All manual
transaxles use SAE 5W-30 engine oil, meeting SG
and/or SG-CC qualifications, as the lubricant to reduce
wear.
The Chrysler 5-speed manual transaxles combine
gear reduction, ratio selection, and differential func-
tions in one unit. It is housed in a die-cast aluminum
case (Fig. 1).
All shift forks are cast iron. Do not interchange 1-2
or 5th shift fork pads with the 3-4 shift fork pads.
All synchronizers use a winged strut design that
prevents the struts from popping out of position.
If any synchronizer is to be disassembled, mark
all parts so that they will be reassembled in the
same position.
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly, or with previous model years tran-
saxles; they will NOT function correctly.
To reduce wear, the manual transaxle uses SAE
5W-30 engine oil as the lubricant.
Gear ratios for the A-523 are as follows:1st-3.31,
2nd-2.06, 3rd-1.36, 4th-0.97, 5th-0.71, Reverse-3.14.
Final drive ratio is 3.77.
IDENTIFICATION
The transaxle model, assembly number, build date,
and final-drive ratio are stamped on a tag that is
attached to the top of the transaxle (Fig. 2).
Certain transaxle assemblies use high-strength
Steel in various gears to provide adequate life in
heavy-duty applications. Therefore, it is impera-
tive that the correct transaxle assembly number
is used when ordering service parts. Also, be sure
Fig. 1 External Transaxle Components
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TRANSAXLE
21 - 1
to reinstall this tag whenever it is removed, so the
information is available for future service.
CAUTION:All gears and shafts must not be inter-
changed with previous model years; they will not
function correctly.
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top of
the clutch housing area.
GEARSHIFT LINKAGE ADJUSTMENT (CABLE OPER-
ATED)
Before replacing the gearshift selector cable or cross-
over cable for a hard-shifting complaint, disconnect
both cables at the transaxle (Fig. 3). Then, from the
driver’s seat, manually operate the gearshift lever
through all gear ranges. If the gearshift lever moves
smoothly, the cable(s) should NOT be replaced.
(1) Working over the left front fender, remove the
lock pin from the transaxle gearshift (selector shaft)
housing (Fig. 4).
(2) Reverse the lock pin (so long end is down) and
insert lock pin into same threaded hole. A hole in the
selector shaft will align with the lock pin, allowing the
lock pin to be screwed into the housing. This operation
locks the selector shaft in the 3-4 neutral position.
(3) Remove or install gearshift knob (Fig. 5 or 6).
(4) Remove or install boot (Fig. 7).
(5) Remove or install selector and crossover cables
(Fig. 8 or 9).
Cable attachment clips must be installed from
the side. Install cable fittings to shifter pins by
pushing with thumb.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw (Fig. 10).
Fig. 2 A-523 Transaxle Identification
Fig. 3 Gearshift Mechanism
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TRANSAXLE
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CAUTION: Proper torque to the crossover cable ad-
justing screw is very important (Fig. 10).
(6) Remove lock pin from gearshift housing and
reinstall lock pin (so long end is up) in gear shift
housing (Fig. 4). Tighten lock pin to 8 N
Im (70 in. lbs.).
(7) Check for shift into first and reverse. Check for
blockout into reverse.
(8) Gearshift mechanism and cables are now func-
tioning properly.
Fig. 4 Manual Transaxle Pinned in the Neutral Posi-
tion to Adjust Gearshift
Fig. 5 Remove Gearshift Knob
Fig. 6 Install Gearshift Knob
Fig. 7 Remove or Install Boot
Fig. 8 Remove Cables
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TRANSAXLE
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IN-CAR TRANSAXLE DISASSEMBLE/ASSEMBLE
The following items can be serviced without remov-
ing the transaxle:
• Gear shift housing
• Synchronizers
• Intermediate shaft speed gears
• Input shaft
• Reverse idler gear and shaft
• Shift forks and pads
• Shift rails
• Roller detents
• Speedometer pinion
• All external covers
Observe following procedure:
(1) Disconnect negative cable from battery.
(2) Remove both shift cables from shift cover levers.
(3) Remove left front wheel and tire assembly and
left splash shield.
(4) Place drain pan under transaxle and remove
transaxle rear end cover.
(5) Push out the fifth fork roll pin and slide the fifth
fork and synchronizer sleeve off the rail/hub.
(6) Remove the fifth hub snap ring, hub assembly
and speed gear.
(7) Remove fifth gear nut and fifth input gear.
(8) Remove the bearing retainer plate, interlock
plate and shuttles.
CAUTION: Before removing the gearshift housing
assembly, reverse the lock pin (so the long end is
down) and insert lock pin into the same threaded
hole. This procedure will save time when the gear
shift housing assembly is reinstalled.
(9) Remove selector shaft housing bolts (note the two
pilot bolts) and remove housing.
(10) Remove roller detents and springs, noting that
the rollers align with the shift rails.
(11) Push out the 1-2 and 3-4 lug roll pins, remove
the reverse pivot lever and fifth rail C-Clip. If a roll
pin or C-Clip falls, be sure to remove it from the
bottom of the case.
(12) Pull out the fifth shift rail and remove the fifth
shift lug and interlock pin.If the pin falls, be sure to
remove it from the bottom of the case.
(13) Remove the intermediate shaft ball bearing
snap ring and the bearing support plate.
(14) Remove reverse shift rail and lug assembly.
(15) Remove the reverse idler shaft and gear assembly.
(16) Rotate the 1-2 shift lug and rail, and 3-4 shift
lug toward the front of the vehicle.
(17) Firmly grasp both the input and intermediate
shaft assemblies and pull them out of the transmission
with the 1-2 and 3-4 shift rails, lugs and forks.
The differential assembly can only be serviced
by removing the complete transaxle from the
vehicle because bearing preload must be reset.
The components listed in the first paragraph can now be serviced.
Refer to the appropriate subassembly recondition section.
To reassemble the transaxle in the vehicle, reverse
the above procedure using the proper sealants. Fill the
transaxle with SAE 5W-30 engine oil to the bottom of
the fill hole in the end cover.
TRANSAXLE REMOVAL AND INSTALLATION
Transaxle removal does not require engine removal.
After installing transaxle, fill transaxle to bottom of
fill plug hole with SAE 5W-30 engine oil before lower-
ing vehicle to floor.
(1) Disconnect or connect negative battery cable.
(2) Install a lifting eye on battery ground strap bolt
on left side of engine and install the engine support
fixture as shown in Figure 11.
(3) Disconnect or connect gearshift cables at tran-
saxle. Disconnect speedometer. Disconnect or connect
gearshift cables bracket at transaxle.
(4) Remove or install both front wheel and tire assemblies.
(5) Remove or install left front splash shield.
(6) Remove or install engine left mount from transaxle.
Fig. 9 Install Cables
Fig. 10 Adjusting Crossover Cable
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TRANSAXLE
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