differential CHRYSLER CARAVAN 2002 Service Manual

bearing during press operation. Repeat the same
operation on opposite side.
(14) Measure and verify differential side gear end
play. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/DIFFERENTIAL - ADJUSTMENTS).
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE
NOTE: Differential turning torque should only be
measured with the geartrain out of the transaxle. If
measurement is taken with transaxle assembled, an
inaccurate measurement will result.
NOTE: All differential cover-to-case bolts and exten-
sion housing-to-case bolts must be installed and
torqued to obtain accurate measurement.
(1) If transaxle is assembled, remove geartrain
and leave differential in place. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL - DISASSEMBLY)
(2) Install differential cover and torque differential
cover-to-case bolts to 54 N´m (40 ft. lbs.).
(3) Install extension housing and torque extension
housing-to-case bolts to 28 N´m (250 in. lbs.).
(4) Place transaxle on work bench so axle center-
line is parallel to the ground.
(5) Install turning torque tool C-4995 to differen-
tial at side opposite extension housing.
(6) Using in. lb./N´m dial indicator, rotate differen-
tial case multiple times and record measurement
(Fig. 123). Differential turning torque should be
within 2.3-3.4 N´m (20-30 in. lbs.). Refer to shim
chart for proper shim selection. If turning torque
measured is less than 2.3 N´m (20 in. lbs.), install a
thicker shim. If turning torque measured is greater
than 3.4 N´m (30 in. lbs.), install a thinner shim.
Fig. 123 Differential Turning Torque Measurement
1 - DIAL TORQUE WRENCH
2 - TOOL C-4995
Fig. 121 Ring Gear-to-Differential Case Bolts
1 - BOLT (12)
2 - DIFFERENTIAL SUPPORT
3 - RING GEAR
Fig. 122 Differential Side Bearing Installation
1 - ARBOR PRESS
2 - INSTALLER 8473
3 - BEARING
4 - BUTTON 8491
21 - 356 T850 MANUAL TRANSAXLERS
DIFFERENTIAL (Continued)
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DIFFERENTIAL BEARING SHIM CHART
PART NUMBERSHIM THICKNESS
METRIC (MM) STANDARD (STD)
4659242 0.50 0.0197
4659243 0.54 0.0213
4659247 0.58 0.0228
4659248 0.62 0.0244
4659249 0.66 0.0260
4659250 0.70 0.0276
4659251 0.74 0.0291
4659252 0.78 0.0307
4659253 0.82 0.0322
4659254 0.86 0.0339
4659255 0.90 0.0354
4659256 0.94 0.0370
4659257 0.98 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
RST850 MANUAL TRANSAXLE21 - 357
DIFFERENTIAL (Continued)
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ADJUSTMENT - DIFFERENTIAL SIDE GEAR
END PLAY
Measure side gear end play: Insert feeler gauges
180É apart between differential side gear and thrust
washer as shown in (Fig. 124). Measurement taken
here applies to both sides. Side gear end play should
be between 0.025-0.152 mm (0.001-0.006 in.). If clear-
ance is greater than 0.152 mm (0.006 in.), install a
thicker thrust washer (both sides). If clearance is less
than 0.025 mm (0.001), install a thinner thrust
washer (both sides). Refer to (Fig. 125) for available
side gear shim thicknesses.
If end play measurement indicates a thrust washer
change is necessary, the differential must be disas-
sembled. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/DIFFERENTIAL - DISASSEMBLY)
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
NOTE: For proper fluid level check intervals, (Refer
to LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
(1) Raise vehicle on hoist.(2) Remove transaxle fill plug (Fig. 126).
(3) Inspect fluid level. Fluid should be within 1/8º
below fill hole. Add MopartATF+4 (Automatic Trans-
mission FluidÐType 9602) as neccessary.
(4) Install fill plug, ensuring it is properly seated.
(5) Lower vehicle.
Fig. 124 Side Gear End Play Measurement
1 - FEELER GAUGE
Fig. 125 Available Side Gear Thrust Washers
1 - (PLAIN) 0.79-0.84 mm (0.031-0.033 in.)
2 - ( TRIANGLE) 0.91-0.97 mm (0.036-0.038 in.)
3 - (SQUARE) 1.04-1.10 mm (0.041-0.043 in.)
4 - (DIAMOND) 1.17-1.22 mm (0.046-0.048 in.)
Fig. 126 Transaxle Fill Plug
1 - FILL PLUG
2 - END COVER
21 - 358 T850 MANUAL TRANSAXLERS
DIFFERENTIAL (Continued)
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STANDARD PROCEDURE - FLUID DRAIN AND
FILL
NOTE: For proper fluid change intervals, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 127) and
drain fluid into suitable container.
(3) Install drain plug and torque to 23 N´m (17 ft.
lbs.).
FLUID FILL
(1) Remove transaxle fill plug (Fig. 128).
(2) Add 2.4-2.7L (2.5-2.9 qts.) of MopartATF+4
(Automatic Transmission FluidÐType 9602) until
fluid is within 1/8º below fill hole.
(3) Install fill plug, ensuring it is properly seated.
(4) Lower vehicle.
GEARSHIFT BOOT
REMOVAL
(1) Remove gearshift knob by pushing down and
rotating1¤4-turn clockwise (Fig. 129).
Fig. 127 Transaxle Drain Plug
1 - TRANSAXLE DRAIN PLUG
2 - DIFFERENTIAL COVER
Fig. 128 Transaxle Fill Plug
1 - FILL PLUG
2 - END COVER
Fig. 129 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RST850 MANUAL TRANSAXLE21 - 359
FLUID (Continued)
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INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 227) is part
of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated pinion gear, and consists of the following com-
ponents:
²Intermediate Mainshaft
²1st Speed Gear
²2nd Speed Gear
²3/4 Cluster Gear
²5th Speed Gear
²Reverse Gear
²1/2 Synchronizer
²5/R Synchronizer
The intermediate shaft is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.
Fig. 227 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
RST850 MANUAL TRANSAXLE21 - 387
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