transmission CHRYSLER VOYAGER 2001 Service Manual

(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 379).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 380). Install
Transmission Range Sensor retaining screw (Fig.
380) and torque to 5 N´m (45 in. lbs.).(16) Install manual shaft seal (Fig. 381).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
382). Install and torque valve body-to-transaxle case
bolts (Fig. 383) to 12 N´m (105 in. lbs.).
Fig. 379 Install Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 380 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 381 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 382 Valve Body Removal/Installation
1 - VALVE BODY
RSAUTOMATIC - 41TE21 - 301
VALVE BODY (Continued)

(2) Install transaxle oil filter (Fig. 384). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-ant to the oil pan and install (Fig. 385). Torque oil
pan-to-transaxle case bolts (Fig. 386) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 383 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 384 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 385 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 386 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21 - 302 AUTOMATIC - 41TERS
VALVE BODY (Continued)

(14) Disconnect back-up lamp switch connector.
(15) Remove structural collar.
(16) Remove modular clutch assembly-to-drive
plate bolts.
(17) Position screw jack and wood block to engine
oil pan.
(18) Remove transmission upper mount through-
bolt from left frame rail.
(19) Lower engine/transaxle assembly on screw
jack.
(20) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 15).
(21) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(22) Remove transaxle from engine.
(23) Inspect modular clutch assembly, clutch
release components, and engine drive plate.
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 13 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 12 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

(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 cradle plate.
(16) Remove front harness retainer and secure
harness out of way.
(17) Remove clutch release access cover.
(18)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 22).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 23). Disengage T-end
from release lever and secure cable out of way.
(19) Remove engine left mount bracket (Fig. 24).
(20) Remove starter motor (Fig. 25).
(21) Disconnect back-up lamp switch connector.
(22) Position screw jack and wood block to engine
oil pan.
(23) Remove transmission upper mount through-
bolt from left frame rail.
(24) Lower engine/transaxle assembly on screw
jack.(25) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 26).
(26) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(27) Remove transaxle from engine (Fig. 27).
(28) Inspect clutch, clutch release components, and
flywheel.
Fig. 22 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 23 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 24 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
RGT850 MANUAL TRANSAXLE21a-15
T850 MANUAL TRANSAXLE (Continued)

(13) Remove end cover-to-case bolts (12) (Fig. 40).
(14) Remove end cover from transaxle (Fig. 41).
(15) Remove 3/4 shift rail bushing from end cover
using slide hammer C-3752 and remover 6786 (Fig.
42).
(16) Remove reverse idler bolt (Fig. 43). Remove
reverse idler gear, washers, and shaft upon geartrain
removal.
(17) Remove 1-2/5-R shift rail (Fig. 44).
(18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 45).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 45).
(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
meaure 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. 46).
Fig. 40 End Cover Bolts
1 - BOLT (12)
Fig. 41 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 42 3/4 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 43 Reverse Idler Shaft Bolt
21a - 20 T850 MANUAL TRANSAXLERG
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)

(3) Install intermediate shaft bearing race to case
with an arbor press, driver handle C-4171, and
installer 8471 (Fig. 53). Press until installer 8471
bottoms on transaxle case.
NOTE: If input shaft assembly was not disassem-
bled, it is necessary to remove input shaft sealed
ball bearing before assembling transaxle. (Refer to
21 - TRANSMISSION/TRANSAXLE/MANUAL/INPUT
SHAFT - DISASSEMBLY)
(4) Install assembled input and intermediate
shafts to fixture 8487 (Fig. 54).
(5) Install shift forks and 3/4 rail assembly to
geartrain as shown in (Fig. 55).
NOTE: Before installing geartrain, make sure that
input shaft sealed roller bearing is not installed,
otherwise reverse idler assembly installation will be
difficult. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/INPUT SHAFT - DISASSEMBLY)
(6) Install lifting bar 8489 to geartrain. Install
geartrain to case.When installing geartrain to
case, use care not to damage bearing surfaces.
Fig. 51 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 52 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
Fig. 53 Install Intermediate Shaft Bearing Race
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - INSTALLER 8471
4 - INTERMEDIATE SHAFT BEARING RACE
RGT850 MANUAL TRANSAXLE21a-23
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)

(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)

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