A/T - A604 Transfer Gear Whine Noise

91chrysler05

NO.: 21-09-91

GROUP: TRANSMISSION

DATE: June 17, 1991


SUBJECT: Transfer Gear Noise A-604 Transaxles


MODELS:

1989-90 (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
1990 (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 27.5~ low lead 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 Shim 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 caused by transfer gears, continue with repair procedure.

PARTS REQUIRED:

1 Transfer Gear Package 4638737


REPAIR PROCEDURE:

This repair involves replacement of the transfer gears with revised gears.

1. With the transaxle in neutral and the steering wheel turned full left, raise the vehicle on the hoist. Remove the left front wheel.

2. Remove the left front inner wheel well splash shield.

3. With a drain pan under vehicle to catch the transaxle fluid, remove the transfer gear cover.

4. Remove the transfer gear nut and washer using special tool # 6259.

5. Install puller tool # L-4407 onto transfer gear and remove gear and shim.

6. Draw or scribe a line from the indexing slot on the bearing cup retainer to the transfer cover bolt flange. (THIS WILL ALLOW BEARING RETAINER TO BE INSTALLED IN ORIGINAL POSITION SHOULD IT COME OUT.)

7. Remove the output gear bolt, washer and shim using tools # L-4407 & # 6259.





8. Install gauging shim .177" (4.50 mm), PN 4412832, and new output gear (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 SHOUID BE VERIFIED WITH A MICROMETER.

9. 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.

10. Measure the end play of the output gear bearing using a dial indicator attached to the transaxle case and record end play. End Play:___________inches.

11. Using an inch-pound torque wrench, check and record the output gear turning torque. Turning Torque:________inch-pounds.

FIGURE 1:

12. With output bearing turning torque determined, refer to the Output Gear Bearing Shim Chart (Figure 1).

13. Using tools # L4407 & # 6259, remove output gear, bolt and washer.

14. Remove gauging shim and install the proper shim selected in step 12. Verify the shim thickness with a micrometer before installing. Using the old retaining bolt & washer, torque to 200 ft.lbs. (271 N-m).


15. Using a dial indicator measure output gear end play. If end play is zero, go to the next step. If end play exists, repeat steps 7-15.

16. Using an inch-pound torque wrench, check and record the output gear turning torque. Turning Torque:__________inch-pounds.

17. Subtract line 11 from line 16. The difference must be 3-8 inch pounds.


NOTE: THIS IS THE OUTPUT BEARING TURNING TORQUE.


18. 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 difference (step 17) is 3-8 inch pounds.

19. Remove old retaining bolt & washer and discard. Install new retaining bolt & washer and torque to 200 ft.lbs. (271 N-m).

20. Install a .183" (4.66 mm) gauging shim, PN 4505588, onto the transfer shaft.

NOTE: BEFORE INSTALLING GEAR MAKE SURE BEARING CUP RETAINER INDEX SLOT LINES UP WITH THE MARK MADE IN STEP 6.

21. Lubricate the bearing on the new transfer gear with ATF 7176, and install the gear using old retaining nut and washer. Torque retaining nut to 200 ft. lbs. (271 N-m).

22. 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.)

(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.

FIGURE 2:

23. Refer to the transfer shaft bearing shim chart (Figure 2) to determine the shim required to obtain the proper setting.

24. Remove the transfer gear using tools L-4407 & # 6259.

25. Remove gauging shim and install the selected shim from step 23.

26. Install transfer gear making sure bearing cup retainer is properly indexed, torque retaining nut to 200 ft.lbs. (271 N-m). (Retainer index tab can be viewed through large hole in gear.)


27. Measure transfer shaft end play as outlined in step 22. 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 22 (b).


28. Remove old retaining nut & washer and discard. Install new retaining nut & washer and torque to 200 ft.lbs. (271 N-m).

29. Install transfer gear cover using R.T.V., torque bolts to 105 in.lbs. (12 N-m).

30. Install wheel well inner splash shield.

31. Install left front wheel and torque lug nuts to 95 ft.lbs. (129 N-m).

32. Fill transaxle to the specified level with ATF 7176 fluid.


POLICY: Reimbursable within the provisions of the warranty.


TIME ALLOWANCE
Labor Operation No. 21-34-04-90 . . . . . . . . 1.7 Hrs.

FAILURE CODE: 68 - Noisy