torque 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)

(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)

(7) Remove lifting bar 8489 from geartrain.
(8) Install shift 1/2-5/R rail as shown in (Fig. 56).
(9) Install reverse idler shaft into position (Fig.
57). Install and torque shaft-to-case bolt to 54 N´m
(40 ft. lbs.).(10) Install reverse idler gear bearing (Fig. 58).
(11) Install reverse idler gear with hub down as
shown in (Fig. 59).
(12) Install flat washer (Fig. 60).
(13) Install wave washer (Fig. 61).
(14) Install input shaft sealed roller bearing using
installer 8482 (Fig. 62).
(15) Installnewinput shaft bearing snap ring
(Fig. 63).
Fig. 54 Install Geartrain to Fixture 8487
1 - INTERMEDIATE SHAFT
2 - INPUT SHAFT
3 - FIXTURE 8487
Fig. 55 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
21a - 24 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

(16) Install shift rail bushing to end cover using
installer 8475 (Fig. 64).
(17) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to transaxle end cover and install to
transaxle case (Fig. 65).While installing end
cover, be sure to guide oil trough into pocket
(Fig. 66).Torque end cover-to-case bolts to 28 N´m
(250 in. lbs.) (Fig. 67).
(18) Install lifting bar 8489 to geartrain.
(19) Lift up on bar (input shaft side) and install
input shaft bearing snap ring (Fig. 68).
(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. 69).
(23) Install back up lamp switch and torque to 23
N´m (17 ft. lbs.) (Fig. 70).
Fig. 64 Shift Rail Bushing Installation
1 - INSTALLER 8475
Fig. 65 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 66 Oil Trough Pocket
1 - OIL TROUGH
2 - POCKET
Fig. 67 End Cover Bolts
1 - BOLT (12)
RGT850 MANUAL TRANSAXLE21a-27
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)

(31) Install input shaft bearing retainer (Fig. 77).
Torque bolts to 12 N´m (105 in. lbs.).
(32) If previously removed, install clutch release
lever pivot ball(s) using slide hammer C-3752 and
remover/installer 6891 (Fig. 78) (Fig. 79) (Fig. 80).
(33) Install clutch release bearing to lever. Apply
grease to interface (contact) points. Make sure
release bearing retainers engage lever pocket as
shown in (Fig. 81).
(34) Apply grease to pivot ball(s), and on RHD
release lever at slave cylinder contact point.
(35) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seatrelease lever to pivot ball(s) (Fig. 82) (Fig. 83). A
ªpopº sound should be heard.Make sure LHD lever
is secured to BOTH pivot balls.Verify proper
engagement by lightly pulling outward on lever at
pivot ball location, and then actuating lever and
bearing to ensure proper operation.
Fig. 76 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 77 Input Bearing Retainer
1 - INPUT BEARING RETAINER
Fig. 78 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 79 Pivot Ball Position (LHD)
1 - PIVOT BALLS (2)
21a - 30 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
Fig. 80 Pivot Ball Position (RHD)
1 - PIVOT BALL (1)
Fig. 81 Release Bearing-to-Lever (LHD ShownÐRHD
Typical)
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 82 Release Bearing and Lever (LHD)
1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 83 Release Bearing and Lever (RHD)
1 - RELEASE LEVER
2 - RELEASE BEARING
RGT850 MANUAL TRANSAXLE21a-31
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)