Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 91
CAUTION: When installing, be sure guide bracket and
split sleeve touch the rear of the transaxle case.
Fig. 74 Guide Bracket Pivot Shaft
Fig. 75 Pivot Shaft and Guide Bracket
Fig. 76 Guide Bracket Assembled
Fig. 77 Guide Bracket Disassembled
Fig. 78 Low/Reverse Clutch Piston
Fig. 79 Piston Retainer Attaching Screws
.
TRANSAXLE
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CAUTION: Drift bearing cup all the way around.
To assemble, reverse the above procedure. Be sure to
check both grounded clutch clearances (Figs. 87 and
88). Before installing the input clutches retainer, follow
the instructions in ‘‘Determining No. 4 Thrust Plate
Thickness’’ (Figs. 89, 90, 91, 92).
Fig. 80 Piston Retainer
Fig. 81 Piston Retainer Gasket
Fig. 82 Remove Output Bearing Inner Cup
Fig. 83 Remove Output Bearing Outer Cup
Fig. 84 Install Both Output Bearing Cups
Fig. 85 Checking Output Gear Bearings End Play
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TRANSAXLE
.
Press down clutch pack with finger and zero dial
indicator. Low/Reverse clutch pack clearance is
1.04 to 1.65mm (.042 to .065 inch).
Select the proper low/reverse reaction plate to
achieve specifications:
Press down clutch pack with finger and zero dial
indicator. The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch). If not within specifica-
tions, the clutch is not assembled properly. There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE THICKNESS
(Input Shaft End Play)
To determine the proper thickness of the No. 4 thrust
plate, select the thinnest No. 4 thrust plate. Using
petrolatum to hold thrust plate in position, install
input clutches assembly. Be sure the input clutches
assembly is completely seated.
Fig. 86 Checking Output Gear Bearings Turning
Torque
Fig. 87 Check Low/Reverse Clutch Clearance
LOW/REVERSE REACTION PLATE CHART
Fig. 88 Check 2/4 Clutch Clearance
Fig. 89 Select Thinnest No. 4 Thrust Plate
.
TRANSAXLE
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CAUTION: If view through input speed sensor hole is
not as shown above, the input clutches assembly is
not seated properly.
CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
By removing the oil pump O-ring, you will be able to
install and remove the oil pump and gasket very easily
to select the proper No. 4 thrust plate.
Input shaft end play must be .005 to .025 inch.
For example, if end play reading is .055 inch, select
No. 4 Thrust Plate which is .071 to .074 thick. This
should provide an input shaft end play reading of .020
inch which is within specifications.
See chart to select the proper No. 4 thrust plate.
INPUT CLUTCHES-RECONDITION
DISASSEMBLY
Tag reverse clutch pack for reassembly identi-
fication.
Fig. 90 View Through Input Speed Sensor Hole
Fig. 91 Remove Oil Pump O-Ring
Fig. 92 Measure Input Shaft End Play
NO. 4 THRUST PLATE CHART
Fig. 1 Tapping Reaction Plate
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TRANSAXLE
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