Chrysler 1998 Voyager, Service Manual, Page: 1660 / 1938

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Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, struts, or springs can cause shift problems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air–powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
The transaxle fill plug is located on the lower left
side of the transaxle end cover. With the vehicle at a
level position, remove the fill plug and check the
level of the lubricant. The lubricant level should be
within 3.175mm (1/8 inch) from the bottom of the fill
hole. If the lubricant level is low, fill the transaxle to
the bottom of the fill hole with SAE 5W-30 engine oil,
meeting SG and/or SG-CD qualifications, as the fac-
tory fill lubricant. SAE GL5 10W-40 engine oil is a
suitable service fill alternative.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
SERVICE PROCEDURES
FLUID DRAIN AND FILL
TRANSAXLE FLUID DRAIN
(1) Hoist vehicle.
(2) Install a drain pan underneath the transaxle
drain plug.
(3) Remove the transaxle drain plug. The drain
plug is located on the bottom of the transaxle hous-
ing.
(4) Let fluid drain out till there is just an occa-
sional drip.
(5) Reinstall drain plug. Tighten drain plug to 28
N·m (250 in. lbs.)
TRANSAXLE FLUID FILL
NOTE: All A-598 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxle fill plug
The fluid level should be within 3.175mm (1/8
inch) from the bottom of the transaxle fill hole (vehi-
cle must be level when checking).
(2) Fill transaxle to proper level with SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications.
G5 SAE 10W-40 engine oil is a suitable service fill
alternative. Dry fill lubricant capacity is approxi-
mately 1.9-2.2 liters (4.0-4.6 pints)..
(3) Wipe the outside of the transaxle if any lubri-
cant spills.
(4) Reinstall transaxle fill plug.
FLUID DRAIN AND FILL—RHD VEHICLES
TRANSAXLE FLUID DRAIN
(1) Hoist vehicle.
(2) Install a drain pan underneath the transaxle
drain plug.
(3) Remove the transaxle drain plug. The drain
plug is located on the bottom of the transaxle hous-
ing (Fig. 5).
(4) Let fluid drain out till there is just an occa-
sional drip.
(5) Reinstall drain plug. Tighten drain plug to 28
N·m (250 in. lbs.)
TRANSAXLE FLUID FILL
NOTE: All A-558 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxle fill plug
21 - 4 A–598 MANUAL TRANSAXLE
NS/GS
DIAGNOSIS AND TESTING (Continued)