differential CHRYSLER VOYAGER 2001 Owners Manual

(27) Remove differential chip collector magnet and
clean (Fig. 47).Magnet is adhered with RTV, and
may require force to remove.
(28) Remove intermediate shaft bearing race with
puller 8472 (Fig. 48).
(29) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 49).
(30) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 50).
Fig. 44 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 45 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 46 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 47 Differential Magnet
1 - MAGNET
RGT850 MANUAL TRANSAXLE21a-21
T850 MANUAL TRANSAXLE (Continued)

ASSEMBLY
NOTE: When assembling this transaxle, always use
NEW snap rings.
NOTE: Before assembling transaxle, differential
turning torque must be measured and adjusted.
(Refer to 21 - TRANSMISSION/TRANSAXLE/MANU-
AL/DIFFERENTIAL - ADJUSTMENTS). Differential
turning torque must be measured with geartrain out
of case.
(1) Install input shaft bearing using an arbor press
and remover/installer 8474 (Fig. 51).
(2) Install shift shaft bushing to case using
installer 8475 (Fig. 52).
Fig. 48 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 49 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 50 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
21a - 22 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

(24) Roll transaxle assembly on side.
(25) Install differential chip collector magnet (Fig.
71). Retain to case with a dab of MopartGear Lube
RTV.(26) Install differential assembly with bearing
races and select shim (Fig. 72). Shim selection was
determined before transaxle assembly (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS).
Fig. 68 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
Fig. 69 End Plate Bolts
1 - BOLT (11)
Fig. 70 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 71 Differential Magnet
1 - MAGNET
21a - 28 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

(27) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to differential cover and install to case.
Torque differential cover-to-case bolts to 54 N´m (40
ft. lbs.).
(28) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to extension housing. Install extension
housing to differential cover and case and torque
bolts to 28 N´m (250 in. lbs.) (Fig. 73).(29) Install both axle output shaft seals using
driver handle C-4171 and installer 8473 (Fig. 74)
(Fig. 75).
(30) Applya1mm(0.04 in.) bead of MopartGasket
Maker to shift cover assembly. Place shift cover and
transaxle geartrain into neutral and install shift cover
(Fig. 76) and torque bolts to 28 N´m (250 in. lbs.).
Fig. 72 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 73 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
Fig. 74 Axle Seal Installation
(Extension Housing Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
Fig. 75 Axle Seal Installation
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
RGT850 MANUAL TRANSAXLE21a-29
T850 MANUAL TRANSAXLE (Continued)

(8) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(10)RHD Models:Install clutch slave cylinder
into position, noting orientation of different sized
lugs (Fig. 85). While depressing inward, rotate slave
cylinder clockwise 60tÉ into position until nylon
locating tab rests within transaxle case cutout, and
hydraulic tube is vertical. Connect ªquick-connectº
connection until an audible ªclickº is heard. Verify
connection by pulling outward on connection.LHD
Models:Insert T-end of clutch release cable into
clutch release lever provision. Route cable through
transaxle case cutout, and seat cable housing with
grommet to transaxle case (Fig. 86).
(11) Install clutch access hole cover.
(12) Install cradle plate.
(13) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(14) Lower vehicle.
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 86 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 32 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9)RHD Models:Install clutch slave cylinder into
position, noting orientation of different sized lugs
(Fig. 92). While depressing inward, rotate slave cyl-
inder clockwise 60É into position until nylon locating
tab rests within transaxle case cutout, and hydraulic
tube is vertical. Connect ªquick-connectº connection
until an audible ªclickº is heard. Verify connection by
pulling outward on connection.LHD Models:Insert
T-end of clutch release cable into clutch release lever
provision. Route cable through transaxle case cutout,
and seat cable housing with grommet to transaxle
case (Fig. 93).
(10) Install clutch access hole cover.
(11) Install cradle plate.
(12) Install underbody splash panel.
(13) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(14) Lower vehicle.
(15) Install right mount bracket to transaxle (Fig.
94).
Fig. 92 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 93 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 94 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RGT850 MANUAL TRANSAXLE21a-35
T850 MANUAL TRANSAXLE (Continued)

(21) Install battery thermal shield and clutch cable
eyelet (LHD only) (Fig. 99). Verify proper clutch cable
routing (LHD models). Cable should be routed over
guide, through eyelet, and around coolant bottle and
wiring harness.
(22) Connect battery cables.
(23) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
SPECIFICATIONS
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 3.46
2nd 2.07 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 3.53
Overall Top Gear 3.12 2.66
Fig. 99 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RGT850 MANUAL TRANSAXLE21a-37
T850 MANUAL TRANSAXLE (Continued)

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.)
INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear 0.66-1.84 mm (0.026-0.072 in.)
2nd Gear 0.66-1.84 mm (0.026-0.072 in.)
5th Gear 0.86-1.54 mm (0.034-0.061 in.)
Reverse 0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear 0.091-0.828 mm (0.004-0.033 in.)
2nd Gear 0.051-0.787 mm (0.002-0.031 in.)
5th Gear 0.102-0.762 mm (0.004-0.030 in.)
Reverse 0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION METRIC STANDARD
Differential Turning Torque 2.3-3.4 N´m 20-30 in. lbs.
Side Gear End Play (each side) 0.025-0.152 mm 0.001-0.006 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential Cover-to-Case 54 40 Ð
Bolt, End Cover-to-Case 28 Ð 250
Bolt, End Cover Plate-to-Cover 28 Ð 250
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Reverse Idler Shaft-to-Case 54 40 Ð
Bolt, Ring Gear-to-Differential Case 95 70 Ð
Bolt, Shift Cover-to-Case 28 Ð 250
Nut, 5th Gear-to-Input Shaft 200 148 Ð
Plug, Drain 23 17 Ð
Screw, Input Bearing Retainer 12 Ð 105
Switch, Back-Up Lamp 23 17 Ð
Vent 7 Ð 60
21a - 38 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

AXLE SEALS
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove one or both front halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
(3) Using a suitable screwdriver, remove one or
both axle seals (Fig. 100).
INSTALLATION
(1) Using driver handle C-4171 and installer 8476,
install axle seals into position (Fig. 101) (Fig. 102).
(2) Install one or both front halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(3) Check transaxle fluid level and adjust if neces-
sary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/FLUID - STANDARD PROCEDURE)
(4) Lower vehicle.
Fig. 100 Axle Seal Removal (Extension Housing
Side Shown)
1 - SCREWDRIVER
2 - AXLE SEAL
3 - EXTENSION HOUSING
Fig. 101 Axle Seal Installation
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
Fig. 102 Axle Seal Installation (Extension Housing
Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
21a - 42 T850 MANUAL TRANSAXLERG

BACK-UP LAMP SWITCH
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect back-up lamp switch connector.
(3) Remove back-up lamp switch (Fig. 103).
INSTALLATION
(1) Install back-up lamp switch (Fig. 103) and
torque to 23 N´m (17 ft. lbs.).
(2) Connect back-up lamp switch connector.
(3) Lower vehicle.
DIFFERENTIAL
DESCRIPTION
The T850 differential is a conventional open
design. It consists of a ring gear and a two-piece dif-
ferential case. The differential case contains the pin-
ion and side gears, three floating pinion shafts, and a
pinion shaft retaining ring (Fig. 104). The differential
case is supported in the transaxle by tapered roller
bearings.
OPERATION
The differential assembly is driven by the interme-
diate shaft via the ring gear. The ring gear drives the
differential case, and the case drives the halfshafts
through the differential gears. The differential pinion
and side gears are supported in the case by pinion
shafts and thrust washers. Differential pinion and
side gears make it possible for front wheels to rotate
at different speeds while cornering.
Fig. 103 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 104 Differential Assembly
1 - RING GEAR
2 - SUPPORT PLATE
3 - SIDE GEAR (2)
4 - PINION GEAR (4)
5 - BOLT (12)
6 - PINION SHAFT (2-SHORT)
7 - PINION SHAFT (1-LONG)
8 - THRUST WASHER (2)
9 - RETAINING RING
10 - DIFFERENTIAL CASE
RGT850 MANUAL TRANSAXLE21a-43