oil CHRYSLER CARAVAN 2003 Service Manual

(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 20).(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove front harness retainer and secure
harness out of way.
(16) Using Tool 6638A, disconnect clutch hydrau-
lic circuit quick connect (located on slave cylinder
tube). Remove clutch slave cylinder by depressing
towards case and rotating counter-clockwise 60É,
while lifting anti-rotation tab out of case slot with
screwdriver (Fig. 21).
(17) Remove engine left mount bracket (Fig. 22).
(18) Remove starter motor (Fig. 23).
(19) Disconnect back-up lamp switch connector.
(20) Position screw jack and wood block to engine
oil pan.
(21) Remove transmission upper mount through-
bolt from left frame rail.
(22) Lower engine/transaxle assembly on screw
jack.
(23) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 24).
Fig. 19 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 20 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 21 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
21 - 34 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(2) Remove input shaft bearing retainer (Fig. 29).
NOTE: Place transaxle in neutral before shift cover
removal.(3) Remove shift cover-to-case bolts and remove
shift cover assembly (Fig. 30).
(4) Using a suitable screwdriver, remove extension
housing axle oil seal (Fig. 31).
Fig. 28 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 29 Input Bearing Retainer
1 - INPUT BEARING RETAINER
Fig. 30 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 31 Extension Housing Seal
1 - SCREWDRIVER
2 - EXTENSION HOUSING
3 - SEAL
RST850 MANUAL TRANSAXLE21-37
T850 MANUAL TRANSAXLE (Continued)
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(12) Remove lifting bar 8489.
(13) Remove end cover-to-case bolts (12) (Fig. 36).
(14) Remove end cover from transaxle (Fig. 37).(15) Remove 3/4 shift rail bushing from end cover
using slide hammer C-3752 and remover 6786 (Fig.
38).
(16) Remove reverse idler bolt (Fig. 39). Remove
reverse idler gear, washers, and shaft upon geartrain
removal.
Fig. 36 End Cover Bolts
1 - BOLT (12)
Fig. 37 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 38 3/4 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 39 Reverse Idler Shaft Bolt
RST850 MANUAL TRANSAXLE21-39
T850 MANUAL TRANSAXLE (Continued)
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(17) Remove 1-2/5-R shift rail (Fig. 40). (18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 41).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 41).
(21) Remove lifting bar from geartrain.
NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(22) Reinstall and torque extension housing and
measure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
(23) Remove differential cover bolts.
(24) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(25) Remove extension housing.
(26) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 42).
Fig. 40 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 41 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 42 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
21 - 40 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(14) Install input shaft sealed roller bearing using
installer 8482 (Fig. 58).
(15) Installnewinput shaft bearing snap ring
(Fig. 59).(16) Install shift rail bushing to end cover using
installer 8475 (Fig. 60).
(17) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to transaxle end cover and install to
transaxle case (Fig. 61).While installing end
cover, be sure to guide oil trough into pocket
(Fig. 62).Torque end cover-to-case bolts to 28 N´m
(250 in. lbs.) (Fig. 63).
Fig. 58 Install Input Shaft Sealed Roller Bearing
1 - INSTALLER 8482
2 - SEALED ROLLER BEARING
Fig. 59 Input Shaft Bearing Snap Ring
1 - SNAP RING
Fig. 60 Shift Rail Bushing Installation
1 - INSTALLER 8475
Fig. 61 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
21 - 46 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(18) Install lifting bar 8489 to geartrain.
(19) Lift up on bar (input shaft side) and install
input shaft bearing snap ring (Fig. 64).
(20) Lift up on bar (intermediate shaft side) and
install intermediate shaft bearing snap ring.
(21) Remove lifting bar 8489.
(22) Install a bead of MopartGear Lube RTV to
end plate and immediately install to case. Install and
torque bolts to 28 N´m (250 in. lbs.) (Fig. 65).
Fig. 62 Oil Trough Pocket
1 - OIL TROUGH
2 - POCKET
Fig. 63 End Cover Bolts
1 - BOLT (12)
Fig. 64 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
Fig. 65 End Cover Bolts
1 - BOLT (11)
RST850 MANUAL TRANSAXLE21-47
T850 MANUAL TRANSAXLE (Continued)
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SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.65
2nd 2.05 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.77
Overall Top Gear 3.12 2.67
INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
21 - 56 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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ASSEMBLY
NOTE: Depending on date of manufacture, some
input shafts will utilize a needle bearing under the
3rd and 4th Speed Gears.
NOTE: When servicing the input shaft assembly, all
snap rings MUST be replaced with new ones upon
assembly. 5th gear nut must also be replaced.
NOTE: When installing 3/4 synchronizer hub to
shaft, make sure to align oil slots on synchronizer
hub face with oil hole in the shaft splined hub jour-
nal.
NOTE: Refer to (Fig. 215) for input shaft assembly
reference.
Fig. 215 Input Shaft Assembly
1 - INPUT SHAFT 6 - 5TH GEAR NUT
2 - THRUST WASHER 7 - SNAP RING
3 - 3RD GEAR 8 - INPUT BEARING (SEALED)
4 - 4TH GEAR 9 - SNAP RING
5 - 5TH GEAR 10 - 3/4 SYNCHRONIZER
Fig. 214 3rd Gear Removal/Installation
1 - 3RD GEAR
21 - 96 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)
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(1) Install input shaft into fixture 8487.
(2) Install thrust washer if removed upon disas-
sembly.
(3) Install 3rd gear and needle bearing (if
equipped) (Fig. 216).
(4) Install 3rd gear blocker ring (Fig. 217).(5) Install 3/4 synchronizer (Fig. 218).When
installing 3/4 synchronizer hub to shaft, make
sure to align oil slots on synchronizer hub face
with oil hole in the shaft splined hub journal.
(6) InstallNEW3/4 synchronizer snap ring (Fig.
219).
Fig. 216 3rd Gear Removal/Installation
1 - 3RD GEAR
Fig. 217 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 218 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 219 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
RST850 MANUAL TRANSAXLE21-97
INPUT SHAFT (Continued)
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ASSEMBLY
NOTE: Depending on date of transaxle manufacture,
some intermediate shafts will utilize a needle bear-
ing under 2nd and 5th Speed Gears.
NOTE: Do not re-use snap rings when servicing the
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.NOTE: When installing 1/2 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 252) for intermediate shaft
assembly reference.
Fig. 252 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 - 107
INTERMEDIATE SHAFT (Continued)
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