joint at the power transfer unit connection. The cen-
ter and rear shaft segments utilize a support bear-
ing/bracket assembly. The rear shaft segment uses a
rubber coupler at the driveline module flange.

OPERATION

The propeller shaft (Fig. 1) is used to transmit

torque from the transaxle power transfer unit (PTU)
to the rear driveline module of AWD equipped mod-
els.

Fig. 1 AWD Driveline

1 - PTU FLANGE
2 - PLUNGING CV JOINT
3 - FRONT SEGMENT
4 - BEARING/SUPPORT
5 - CENTER SEGMENT

6 - BEARING/SUPPORT
7 - REAR SEGMENT
8 - REAR DRIVELINE MODULE
9 - RUBBER COUPLER

PROPELLER SHAFT

3 - 25

The propeller shaft front segment utilizes a plung-

ing CV joint at the PTU flange, and a plunging CV
joint at the center bearing location. These joints are
flexible, allowing for torsional movement of the pow-
ertrain.

The propeller shaft center and rear segments uti-

lize a support bearing/bracket, which support this
three-piece assembly and isolates driveline vibrations
from the body. The rubber coupler at the driveline
module flange dampens out propeller shaft torsional
vibrations, as the driveline module it connects to is
fastened to the rear suspension crossmember.

REMOVAL

CAUTION: Propeller shaft removal is a two-man
operation. Never allow propeller shaft to hang from
the center bearing, or while only connected to
power transfer unit (PTU) or rear driveline module
flanges. A helper is required. If a propshaft section
is hung unsupported, damage may occur to the
joint, boot, and/or center bearing from over-angula-
tion. This may result in driveline vibrations.

(1) Raise vehicle on hoist.
(2) Remove hanger at rear muffler.
(3) Remove exhaust system center hanger brackets

(Fig. 3) and support exhaust system with screw jack.

(4) Make sure transaxle is in neutral (N). Using

chalk, mark propeller shaft flanges at PTU and rear
driveline module for installation reference.

(5) Remove six propeller shaft-to-power transfer

unit bolts (Fig. 2), but do not remove from PTU at
this time.

NOTE: Rubber coupler is part of the propeller shaft
assembly. Removing coupler from propeller shaft
will result in vibration/balance issues.

(6) Remove three propeller shaft rubber coupler-to-

driveline module bolts, but do not remove from driv-
eline module at this time.

(7) Have helper support front segment by hand

while removing center segment bearing/support-to-
body bolts. Support front and center segments by
hand (Fig. 3).

(8) While manually supporting front and center

segments, have helper support rear segment while
removing rear segment bearing/support (Fig. 3).

(9) Lower propeller shaft assembly to ground,

using care not to damage fore and aft flanges (Fig.
3).

INSTALLATION

CAUTION: Propeller shaft installation is a two-man
operation. Never allow propeller shaft to hang while

connected to power transfer unit (PTU), rear driv-
eline module flanges or center bearings. If propeller
shaft section is hung unsupported, damage may
occur to joint, boot and/or center bearing from
over-angulation. This may result in vibration/bal-
ance issues. A helper is required.

(1) Make sure transaxle is in Neutral (N) position.
(2) Obtain a helper and lift propeller shaft assem-

bly into position (Fig. 3). Load shaft to driveline mod-
ule first, and then PTU flange.

(3) Install center and rear support bearing/bracket

assemblies into position. Install bolts hand-tight.

(4) Align paint index marks at driveline module

flange and install three propeller shaft rubber cou-
pler-to-rear driveline module bolts by hand. Torque
propeller shaft rubber coupler-to-rear driveline mod-
ule assembly bolts to 54 N·m (40 ft. lbs.).

(5) Align chalk index marks at PTU flange. Install

six propeller shaft-to-PTU flange bolts (Fig. 2) and
torque to 30 N·m (22 ft. lbs.). Torque bolts alternately
to ensure proper flange mating.

(6) Place center and rear bearing/supports into

position. Install and torque support/bearing-to-body
bolts to 54 N·m (40 ft. lbs.).

(7) Raise exhaust system into position. Install

muffler rear hanger. Remove support stand.

(8) Install exhaust system center hanger
(9) Lower vehicle.

Fig. 2 Propeller Shaft at PTU

1 - BOLT (6)
2 - PTU FLANGE
3 - PROPELLER SHAFT

3 - 26

PROPELLER SHAFT

PROPELLER SHAFT (Continued)

SPECIFICATIONS - PROPELLER SHAFT

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Bolt, Propeller Shaft Front

Flange-to-PTU Flange

—

Bolt, Propeller Shaft Rear

Flange-to-Driveline

Module Flange

—

Bolt, Support/Bearing-to-

Body

—

Fig. 3 Propeller Shaft at Body and Driveline Module

1 - FRONT SEGMENT
2 - CENTER SUPPORT/BEARING
3 - CENTER SEGMENT
4 - REAR SUPPORT/BEARING
5 - BOLT (2)
6 - RUBBER COUPLER

7 - REAR DRIVELINE MODULE
8 - BOLT (3)
9 - SUPPORT BRACKET
10 - BOLT (4)
11 - EXHAUST/HANGER
12 - BOLT (2)

PROPELLER SHAFT

3 - 27

PROPELLER SHAFT (Continued)

REAR DRIVELINE MODULE

TABLE OF CONTENTS

page

REAR DRIVELINE MODULE

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 28

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - REAR

DRIVELINE MODULE NOISE . . . . . . . . . . . . . 29

DIAGNOSIS AND TESTING - REAR

DRIVELINE MODULE OPERATION . . . . . . . . 30

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . 33

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 40

SPECIFICATIONS - REAR DRIVELINE

MODULE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . 42

BI-DIRECTIONAL OVERRUNNING CLUTCH

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 42

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 44

DIFFERENTIAL ASSEMBLY

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 47

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FLUID - DIFFERENTIAL ASSEMBLY

STANDARD PROCEDURE - DIFFERENTIAL

ASSEMBLY FLUID CHANGE

. . . . . . . . . . . . . 48

FLUID - OVERRUNNING CLUTCH HOUSING

STANDARD PROCEDURE - OVERRUNNING

CLUTCH HOUSING FLUID CHANGE

. . . . . . . 49

INPUT FLANGE SEAL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 51

OUTPUT SEAL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 53

VISCOUS COUPLER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 53

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 53

REAR DRIVELINE MODULE

DESCRIPTION

The rear driveline module assembly (Fig. 1) con-

sists of three main components:

• Bi-Directional Overrunning Clutch (BOC)

• Viscous Coupling

• Differential Assembly
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

t ATF+4.

The differential assembly requires Mopar

t 75W-90

Gear and Axle Lubricant.

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 Shaft, Output Shaft, Overrunning

Clutch Housing O-rings)

• Input Flange/Shield

• 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. This vari-
able 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 adjust-
ment, maintenance or fluid checks required during
the life of the unit.

The overrunning clutch allows the rear wheels to

overrun the front wheels during a rapid front wheel
lock braking maneuver. The overrunning action pre-
vents any feed-back of front wheel braking torque to

3 - 28

REAR DRIVELINE MODULE

Content .. 437 438 439 440 ..