A-604 A/T - Transfer Gear Noise/Whine
91chrysler08
NO.: 21-10-91
GROUP: TRANSMISSION
DATE: JULY 1, 1991
SUBJECT: Transfer Gear Noise/Whine A-604 Transaxle
MODELS:
1991 (AA) ACCLAIM/SPIRIT/LeBARON
(AC) DYNASTY/NEW YORKER/LANDAU/SALON
(AG) DAYTONA (AJ) LeBARON COUPE/LeBARON CONVERTIBLE
(AS) CARAVAN/GRAND CARAVAN/CARAVAN C/V
VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
(AY) IMPERIAL/NEW YORKER FIFTH AVENUE
(AQ) CHRYSLER'S TC (MASERATI COUPE)
SYMPTOM/CONDITION:
Vehicle exhibits a high frequency whine (transfer gear noise) at any vehicle speed, either during acceleration or coasting. The condition can now be reduced with the replacement of the transfer gears with new 32~ gears.
NOTE: THIS TECHNICAL SERVICE BULLETIN SHOULD NOT BE ATTEMPTED UNLESS THE DEALERSHIP HAS THE FOLLOWING SPECIAL TOOLS.
^ 0-1" Micrometer or Vernier Caliper
^ Bearing Gauging Shims Part # 's 4412832, 4505588
^ Output & Transfer Bearing Shim Assortment
^ Special Tools L-4432, L-4407, & # 6259
^ 0-25 Inch Pound Beam/or Dial Torque Wrench
^ Foot Pound Torque Wrench
DIAGNOSIS:
Drive the vehicle and verify that the noise is transfer gears. (Usually a High Pitch Noise like a Jet Engine). If Noise is transfer gears, continue with repair procedure.
PARTS REQUIRED:
AS Models with All Wheel Drive, &
AY Models equipped with 3.8L engine Package 4713139
AA, AC, AG, AJ, AS, AY & AQ (FWD) Models
equipped with 3.0L or 3.3L engine Package 4713140
ALL MODELS AS REQUIRED - TRANSFER GEAR END COVER PN 4567255
REPAIR PROCEDURE:
This repair involves the removal of the transaxle, and the complete disassembly of the transaxle to install the revised transfer gears.
REFER TO THE APPROPRIATE SERVICE MANUAL FOR THE DETAILS IN PERFORMING THE FOLLOWING OPERATIONS.
1. Remove the transaxle.
2. Remove the input speed sensor.
3. Remove oil pump.
4. Remove input clutch assembly, front sun gear, carrier and rear annulus assemblies.
NOTE: TAG ALL CLUTCH PACK ASSEMBLIES, AS THEY ARE REMOVED, FOR REASSEMBLY IDENTIFICATION.
CAUTION: DO NOT INTERMIX CLUTCH DISCS OR PLATES.
5. Remove the rear sun gear, and 2/4 clutch pack.
6. Remove low/reverse clutch pack.
7. Remove the transfer gear cover.
8. Remove the transfer gear retaining nut and washer, using tool # 6259.
9. Using special tool L-4407, remove transfer gear.
10. Remove output gear retaining bolt and washer, using tool # 6259.
11. Using special tool L-4407, remove output gear.
12. Remove Rear Carrier. (Part must be returned for claims payment.)
13. Install new Carrier PN 4713145.
NOTE: REAR CARRIER MUST BE REPLACED, OR TRANSAXLE FAILURE MAY OCCUR.
FIGURE 1:
SPECIAL INSTRUCTIONS FOR INSTALLATION OF NEW TRANSFER GEARS
14. Install new output gear using .177 " (4.50 mm) gauging shim PN 4412832, (lubricate bearing with ATF 7176 before installing on output shaft) using old bolt & washer. Torque to 200 ft.lbs. (271 N-m).
NOTE: SHIM THICKNESS SHOULD BE VERIFIED WITH A MICROMETER.
15. Attach tool L-4432 to output gear, push and pull on the gear while turning it back and forth to assure the bearing rollers are seated.
16. Measure the end play of the output gear bearing using a dial indicator attached to the transaxle case.
17. With bearing end play determined, refer to the output gear bearing shim chart (Figure 1) for the required shim to obtain the proper bearing setting.
18. Using tool # 6259, remove the output gear retaining bolt and washer. Remove output gear with tool L-4407.
19. Remove gauging shim and install the proper shim selected in step 17. Install the output gear and bearing assembly, using old retaining bolt and washer. Torque to 200 ft.lbs. (271 N-m).
20. Using a 0-25 inch pound torque wrench, check the output gear turning torque. The turning torque should be 3 to 8 inch pounds.
If the turning torque is too high, install a .0016 inch (.04 mm) thicker shim. If the turning torque is too low, install a .0016 inch (.04 mm) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds.
21. Remove old retaining bolt and washer and save for claims payment.
22. Install new retaining bolt and washer and torque to 200 ft.lbs. (271 N-m).
23. Install .184 inch (4.66 mm) gauging shim on the transfer shaft.
NOTE: SHIM THICKNESS SHOULD BE VERIFIED WITH A MICROMETER.
24. Install the new Transfer Gear and bearing assembly, making sure bearing cup retainer is properly indexed (lubricate bearing with ATF 7176 before installing it on output shaft). Using old nut and washer torque to 200 ft. lbs. (271 N-m).
25. To measure transfer shaft end play:
(a) Install tool L-4432 to the transfer gear.
(b) Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play.)
FIGURE 2:
(c) Push and pull the gear while rotating back and forth to insure the bearing rollers are seated.
(d) Using a dial indicator, measure the transfer shaft end play.
26. Refer to the transfer shaft bearing shim chart (Figure 2) to determine the shim required to obtain the proper setting.
27. Using Tool # 6259, remove the transfer gear retaining nut and washer. Use Tool L-4407 to remove transfer gear.
28. Remove the gauging shim and install the proper shim selected in step 26.
29. Install transfer gear making sure bearing cup retainer is properly indexed, torque old retaining nut to 200 ft.lbs. (271 N-m). (Retainer index tab can be viewed through large hole in gear.)
30. Measure transfer shaft end play as outlined in step 25. End play should be .002" to .004" (.05 mm to .10 mm). If end play is too high, install a .0016" (.04 mm) thinner shim. If end play is too low, install a .0016" (.04 mm) thicker shim. Repeat until .002" to .004" (.05 mm to .10 mm) end play is obtained.
NOTE: REMOVE STEEL BALL INSTALLED IN STEP 25 (b).
31. Remove old retaining nut & washer and save for claim payment. Install new retaining nut & washer and torque to 200 ft.lbs. (271 N-m).
32. Install transfer gear cover (revised cover PN 4567255 if required) using R.T.V., torque bolts to 105 in.lbs. (12 N-m).
NOTE: DO NOT INSTALL END COVER WITH SINGLE BUMP/HUMP OR THE COVER WILL HIT OUTPUT GEAR BOLT.
REFER TO THE APPROPRIATE SERVICE MANUAL FOR THE DETAILS IN ASSEMBLING THE TRANSAXLE.
33. Assemble transaxle in the reverse order using gasket and seal kit supplied.
34. Install the transaxle.
35. Fill transaxle to the specified level with ATF 7176 fluid.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
Labor Operation No. 21-34-04-91 . . . . . . . . 5.9 Hrs.
Optional Equipment:
ABS 21-00-05-63 . . . . . . . . 0.2 Hrs.
All Wheel Drive 21-00-05-64 . . . . . . . . 1.2 Hrs.
FAILURE CODE: 68 - Noisy