CHRYSLER VOYAGER 2001 Service Manual

(5)2.4L Gas models goto Step 10. 2.5L TD
models:Install coolant recovery bottle bracket (Fig.
181).
(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 182).(8) Install battery, hold-down clamp, and nut (Fig.
183).
(9) Install battery thermal shield (Fig. 184).
Fig. 181 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 182 Battery Tray
1 - BATTERY TRAY
Fig. 183 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 184 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RGT850 MANUAL TRANSAXLE21a-65
GEARSHIFT CABLE - SELECTOR (Continued)

(10) Install selector cable to gearshift mechanism
(Fig. 185). Install retainer clip (Fig. 186).(11) Install center console support bracket (Fig.
187). Torque support bracket-to-gearshift mechanism
screws to 12 N´m (108 in. lbs.).
(12) Install center console assembly (Fig. 188).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
Fig. 185 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 186 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 187 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 188 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
21a - 66 T850 MANUAL TRANSAXLERG
GEARSHIFT CABLE - SELECTOR (Continued)

(13) Install cupholder plugs (Fig. 189).
(14) Install gearshift boot to console (Fig. 190).
Secure with three (3) retainer clips.
(15) Install gearshift knob to gearshift lever (Fig.
191). Orient shift pattern ò-turn clockwise, push
down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(16) Connect battery negative cable.
GEARSHIFT KNOB
REMOVAL
(1) Separate gearshift boot from base of knob.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clockwise (Fig. 192).
INSTALLATION
(1) Install gearshift knob pattern ò-turn clock-
wise, press down, and rotate ò-turn counter clock-
wise (Fig. 192).
(2) Secure gearshift boot to base of knob.
Fig. 189 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 190 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 191 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 192 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-67
GEARSHIFT CABLE - SELECTOR (Continued)

GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò turn clock-wise (Fig. 193).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 194).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
195).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
196).
Fig. 193 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 194 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 195 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 196 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
21a - 68 T850 MANUAL TRANSAXLERG

(7) Remove center console support bracket (Fig.
197).
(8) Remove crossover cable retainer clip (Fig. 198).(9) Remove crossover cable from gearshift mecha-
nism (Fig. 199).
(10) Remove selector cable retainer clip (Fig. 200).
Fig. 197 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 198 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 199 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 200 Selector Cable Retainer Clip
1 - RETAINER CLIP
RGT850 MANUAL TRANSAXLE21a-69
GEARSHIFT MECHANISM (Continued)

(11) Remove selector cable from gearshift mecha-
nism (Fig. 201).
(12) Remove four (4) gearshift mechanism-to-park
brake bracket nuts. Remove gearshift mechanism
from bracket (Fig. 202).INSTALLATION
(1) Install gearshift mechanism to park brake
bracket (Fig. 203). Install and torque nuts to 12 N´m
(108 in. lbs.).
(2) Install selector cable to gearshift mechanism
(Fig. 204). Install retainer clip (Fig. 205).
Fig. 201 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 202 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 203 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 204 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
21a - 70 T850 MANUAL TRANSAXLERG
GEARSHIFT MECHANISM (Continued)

(3) Install crossover cable to gearshift mechanism
(Fig. 206). Install retainer clip (Fig. 207).(4) Adjust crossover cable.
(5) Install center console support bracket (Fig.
208). Torque support bracket-to-gearshift mechanism
screws to 12 N´m (108 in. lbs.).
Fig. 205 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 206 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 207 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 208 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
RGT850 MANUAL TRANSAXLE21a-71
GEARSHIFT MECHANISM (Continued)

(6) Install center console assembly (Fig. 209).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(7) Install cupholder plugs (Fig. 210).(8) Install gearshift boot to console (Fig. 211).
Secure with three (3) retainer clips.
(9) Install gearshift knob to gearshift lever (Fig.
212). Orient shift pattern ò-turn clockwise, push
down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 209 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 210 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 211 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 212 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21a - 72 T850 MANUAL TRANSAXLERG
GEARSHIFT MECHANISM (Continued)

INPUT SHAFT
DESCRIPTION
The input shaft assembly (Fig. 213) is part of the
transaxle geartrain, is driven by the clutch assembly,
and consists of the following components:
²Input Mainshaft
²3rd Speed Gear
²4th Speed Gear
²3/4 Synchronizer
²5th Input Gear
The input shaft meshes with the intermediate
shaft, and is supported by a needle bearing at the
front of the transaxle, and a sealed roller bearing at
the rear of the transaxle.
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. 213
RGT850 MANUAL TRANSAXLE21a-73

DISASSEMBLY
NOTE: When servicing the input shaft assembly, all
snap rings which are removed MUST be replaced
with new snap rings upon reassembly. The 5th gear
nut must be replaced also.
(1) Invert input shaft assembly and place in fix-
ture 8487.
(2) Remove input bearing snap ring (Fig. 214).
(3) Remove input bearing. Place input shaft
assembly onto arbor press table, with the input bear-
ing supported by bearing splitter (Fig. 215). Using
adapter 8486-4, press bearing off of shaft, while
helper supports shaft to prevent dropping.
(4) Place input shaft assembly back into fixture
8487. Secure fixture to bench with fasteners, or
secure to bench vise.
NOTE: 5th gear nut is staked to the shaft. If neces-
sary, grind stake area to ease removal, but use care
not to contact gear.(5) Remove 5th gear nut with wrench 8478 (Fig.
216). Discard nut and use a new one upon assembly.
Fig. 214 Input Bearing Snap Ring Removal
1 - SNAP RING
2 - INPUT BEARING
Fig. 215 Input Bearing Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - INPUT BEARING
4 - BEARING SPLITTER
Fig. 216 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
21a - 74 T850 MANUAL TRANSAXLERG
INPUT SHAFT (Continued)