Chrysler Dodge Caravan 2002 Manual page 103

3 - 24 REAR DRIVELINE MODULE
REAR DRIVELINE MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REAR
DRIVELINE MODULE NOISE . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - REAR
DRIVELINE MODULE OPERATION . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
SPECIFICATIONS - REAR DRIVELINE
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 35
BI-DIRECTIONAL OVERRUNNING CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIFFERENTIAL ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
REAR DRIVELINE MODULE
DESCRIPTION
The rear driveline module assembly (Fig. 1) con-
sists of four main components:
• Bi-Directional Overrunning Clutch (BOC)
• Viscous Coupling
• Differential Assembly
• Torque Arm
The viscous coupling and bi-directional overrun-
ning clutch are contained within an overrunning
clutch housing, which fastens to the differential
assembly. The overrunning clutch housing and differ-
ential assembly have unique fluid sumps, each
requiring their own type and capacity of fluid. The
overrunning clutch housing requires Mopar ATF+4
(Automatic Transmission Fluid-Type 9602) or equiv-
alent. The differential assembly requires
Driveline module service is limited to the following
components:
• Differential Assembly (serviced only as assem-
bly)
• Viscous Coupling
• Bi-Directional Overrunning Clutch (BOC)
• Overrunning Clutch Housing
• Seals (Input Flange, Output Flange, Overrun-
ning Clutch Housing O-rings)
REAR DRIVELINE MODULE
TABLE OF CONTENTS
page
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FLUID - DIFFERENTIAL ASSEMBLY
STANDARD PROCEDURE - DIFFERENTIAL
ASSEMBLY FLUID DRAIN AND FILL
FLUID
STANDARD PROCEDURE - OVERRUNNING
CLUTCH HOUSING FLUID CHANGE
VISCOUS COUPLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TORQUE ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
INPUT FLANGE SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
OUTPUT FLANGE SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
• Input Flange/Shield
• Torque Arm
• Vents
• Fasteners
OPERATION
The primary benefits of All Wheel Drive are:
• Superior straight line acceleration, and corner-
ing on all surfaces
• Better traction and handling under adverse con-
ditions, resulting in improved hill climbing ability
and safer driving.
The heart of the system is an inter-axle viscous
coupling. The vehicle retains predominantly front-
wheel drive characteristics, but the All Wheel Drive
capability takes effect when the front wheels start to
slip. Under normal level road, straight line driving,
100% of the torque is allocated to the front wheels.
The viscous coupling controls and distributes torque/
power to the rear wheels. The viscous coupling trans-
mits torque to the rear wheels in proportion of the
amount of the slippage at the front wheels. Thais
variable torque distribution is automatic with no
driver inputs required. The coupling is similar to a
multi-plate clutch. It consists of a series of closely
spaced discs, which are alternately connected to the
front and rear drive units. The unit is totally sealed
and partially filled with silicone fluid. There is no
RS
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