Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 82
CAUTION: Side gear end play must be within .001 to
.013 inch.
Four select thrust washers are available: .032,
.037, .042, and .047 inch.
DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of the
following parts are replaced:
• Transaxle case
• Differential carrier
• Differential bearing retainer
• Extension housing
• Differential bearing cups and cones
Refer to ‘‘Bearing Adjustment Procedure’’ in rear of
this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
Fig. 19 Differential Gears
Fig. 20 Checking Side Gear End Play
Fig. 21 Checking Side Gear End Play
Fig. 22 Remove Oil Seal
Fig. 23 Install New Oil Seal
.
TRANSAXLE
21 - 77
When rebuilding, reverse the above procedure.
Remove old before applying new sealant. Use
Mopar
t Silicone Rubber Adhesive Sealant or
equivalent on retainer to seal retainer to case.
Fig. 24 Remove Bearing Cup
Fig. 25 Differential Bearing Retainer
Fig. 26 Install Bearing Cup
Fig. 27 Checking Differential End Play
Fig. 28 Tool L-4436 and Torque Wrench
Fig. 29 Checking Differential Bearings Turning
Torque
21 - 78
TRANSAXLE
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BEARING ADJUSTMENT PROCEDURES
GENERAL RULES ON SERVICING BEARINGS
(1) Take extreme care when removing and in stalling
bearing cups and cones. Use only an arbor press for
installation, as a hammer may not properly align the
bearing cup or cone. Burrs or nicks on the bearing seat
will give a false end play reading, while gauging for
proper shims. Improperly seated bearing cup and cones
are subject to low-mileage failure.
(2) Bearing cups and cones should be replaced if they
show signs of pitting or heat distress.
If distress is seen on either the cup or bearing rollers,
both cup and cone must be replaced.
Bearing end play and drag torque specifica-
tions must be maintained to avoid premature
bearing failures.
Used (original) bearing may lose up to 50
of the original drag torque after break-in.
All bearing adjustments must be made with no
other component interference or gear inter-
mesh, except the transfer gear bearing.
OUTPUT SHAFT BEARING
With output shaft gear removed.
(1) Install a 13.65 mm (.537 inch) and a 1.34 mm
(.053 inch) gauging shims on the planetary rear annu-
lus gear hub using grease to hold the shims in place.
The 13.65 mm shim has a larger inside diameter and
must be installed over the output shaft first. The 1.34
mm shim pilots on the output shaft.
(2) Install output shaft gear and bearing assembly,
torque to 271 N
Im (200 ft. lbs.).
(3) To measure bearing end play:
(a) Attach Tool L-4432 to the output shaft gear.
(b) Mount a steel ball with grease into the end of
the output shaft.
(c) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(d) Using a dial indicator, mounted to the tran-
saxle case, measure output shaft end play.
(4) Once bearing end play has been determined,
refer to the output shaft bearing shim chart for the
required shim combination to obtain proper bearing
setting.
(a) The 12.65 mm (.498 inch), 13.15 mm (.518 inch)
or 13.65 mm (.537 inch) shims are always installed
first. These shims have lubrication slots which
are necessary for proper bearing lubrication.
(b) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and
output shaft bearings.
(5) Use Tool L-4434 to remove the retaining nut and
washer. To remove the output shaft gear use Tool
L-4407.
(6) Remove the two gauging shims and install the
proper shim combination, making sure to install the
12.65, 13.15, or 13.65 mm shim first. Use grease to hold
the shims in place. Install the output shaft gear and
bearing assembly.
(7) Install the retaining nut and washer and torque
to 271 N
Im (200 ft. lbs.).
(8) Using an inch-pound torque wrench, check the
turning torque. The torque should be between 3
and 8 inch-pounds.
If the turning torque is too high, install a .05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a .05 mm (.002 inch) thinner shim. Repeat
until the proper turning torque is 3 to 8 inch pounds.
DIFFERENTIAL BEARING
(1) Remove the bearing cup from the differential
bearing retainer using Tool L-4518, and remove the
existing shim from under the cup.
(2) Install a .50 mm (.020 inch) gauging shim and
reinstall the bearing cup into the retainer. Use an
arbor press to install the cup.
Oil Baffle is not required when making shim
selection.
OUTPUT SHAFT BEARING SHIM CHART
.
TRANSAXLE
21 - 79
(3) Install the bearing retainer into the case and
torque bolts to 28 N
Im (250 in. lbs.).
(4) Position the transaxle assembly vertically on the
support stand and install Tool L-4436 into the exten-
sion.
(5) Rotate the differential at least one full revolution
to ensure the tapered roller bearings are fully seated.
(6) Attach a dial indicator to the case and zero the
dial indicator. Place the indicator tip on the end of Tool
L-4436.
(7) Place a large screwdriver to each side of the ring
gear and lift. Check the dial indicator for the amount of
end play.
CAUTION: Do not damage the transaxle case and/or
differential cover sealing surface.
(8) When the end play has been determined, refer to
the Differential Bearing Shim Chart for the correct
shim combination to obtain the proper bearing setting.
(9) Remove the differential bearing retainer. Re-
move the bearing cup and the .50 mm (.020 inch)
gauging shim.
(10) Install the proper shim combination under the
bearing cup. Make sure the oil baffle is installed
properly in the bearing retainer, below the bearing
shim and cup.
(11) Install the differential bearing retainer. Seal
the retainer to the housing with Mopar
t Silicone
Rubber Adhesive Sealant or equivalent and torque
bolts to 28 N
Im (250 in. lbs.).
(12) Using special Tool L-4436 and an inch-pound
torque wrench, check the turning torque of the differ-
ential. The turning torque should be between 5
and 18 inch-pounds.
If the turning torque is too high, install a .05
mm (.002 inch) thinner shim. If the turning
torque is too low, install a .05 mm (.002 inch)
thicker shim. Repeat until 5 to 18 inch-pounds
turning torque is obtained.
TRANSFER SHAFT BEARING
(1) Use Tool L-4434 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407.
(2) Install a 2.29 mm (.090 inch) and a 1.39 mm (.055
inch) gauging shims on the transfer shaft behind the
governor support.
(3) Install transfer shaft gear and bearing assembly
and torque the nut to 271 N
Im (200 ft. lbs.).
(4) To measure bearing end play:
(a) Attach Tool L-4432 to the transfer gear.
(b) Mount a steel ball with grease into the end of
the transfer shaft.
(c) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(d) Using a dial indicator, measure transfer shaft
end play.
(5) Refer to the Transfer Bearing Shim Chart for the
required shim combination to obtain the proper bear-
ing setting.
(6) Use Tool L-4434 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407.
(7) Remove the two gauging shims and install the
correct shim combination. Install the transfer gear and
bearing assembly.
(8) Install the retaining nut and washer and torque
to 271 N
Im (200 ft. lbs.). Measure transfer shaft end
play, end play should be .05 to .25 mm (.002 to .010
inch).
(9) Measure bearing end play as outlined in Step (4).
End play should be between .05 mm and .25 mm (.002
to .010 inch).
DIFFERENTIAL BEARING SHIM CHART
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TRANSAXLE
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