torque CHRYSLER VOYAGER 2001 Service Manual

(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)

(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)

(7) Install 4th gear blocker ring (Fig. 229).
(8) Install 4th gear (Fig. 230).
(9) Install 5th gear and press into position using
installer 8481 (Fig. 231).
(10) InstallNEW5th gear nut and torque to 200
N´m (148 ft. lbs.) using wrench 8478 (Fig. 232).
(11) Stake 5th Gear nut as follows:
(a) Install staking tool 8479 to 5th gear nut.(b) Tighten upper thumb screw by hand (Fig.
233).
(c) Tighten two (2) side thumb screws by hand.
Fig. 229 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 230 4th Gear Removal/Installation
1 - 4th GEAR
Fig. 231 5th Gear Installation
1 - ARBOR PRESS RAM
2 - INSTALLER 8481
3 - 5TH GEAR
Fig. 232 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
RGT850 MANUAL TRANSAXLE21a-79
INPUT SHAFT (Continued)

(2) Install springs into hub slot.
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key.
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position.
VEHICLE SPEED SENSOR
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the speed sensor connector (Fig.
288).
CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.(3) Remove speed sensor retaining bolt (Fig. 288).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into trans-
axle. Should sensor drive gear fall into the trans-
axle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) Install pinion gear to speed sensor (Fig. 288) .
(2) Using a NEW o-ring, install the speed sensor
to the transaxle (Fig. 288) .
(3) Install the bolt and torque to 7 N´m (60 in.
lbs.).
(4) Connect speed sensor connector (Fig. 288) .
(5) Lower vehicle and road test to verify proper
speedometer operation.
Fig. 287 1/2 Synchronizer Assembly
1 - SLEEVE
2 - REACTOR RING (2)
3 - HUB
4 - BLOCKER RING (2)
5 - SLEEVE
6 - FRICTION CONE (2)
7 - SPRING (3)
8 - KEY (3)
9 - BALL (3)
Fig. 288 Speed Sensor and Pinion Removal/
InstallationÐTypical
1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - GEAR
21a - 96 T850 MANUAL TRANSAXLERG
SYNCHRONIZER (Continued)

(3) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 15).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 15).
This will hold the wheel cover in place.(4) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 12).
(5) Progressively tighten all five wheel mounting
nuts in the proper sequence (Fig. 16). Tighten wheel
nuts to a torque of 135 N´m (100 ft. lbs.).
(6) Lower the vehicle.
TIRES
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 17).
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 15 WHEEL COVER INSTALLATION OVER TWO
NUTS
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 16 NUT TIGHTENING SEQUENCE
22 - 8 TIRES/WHEELSRS
TIRES/WHEELS (Continued)

Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²The vehicle to drift.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL
SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
Under inflation causes rapid shoulder wear, tire
flexing, and can result in tire failure (Fig. 20).
Over inflation causes rapid center wear and loss of
the tire's ability to cushion shocks (Fig. 21).STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
DaimlerChrysler Corporation advocates driving at
safe speeds within posted speed limits. Where speed
limits allow the vehicle to be driven at high speeds,
correct tire inflation pressure is very important.
Vehicles loaded to maximum capacity should not be
driven at continuous speeds over 120 km/h (75 mph).
Never exceed the maximum speed capacity of the
tire. For information on tire identification and speed
ratings, (Refer to 22 - TIRES/WHEELS/TIRES -
DESCRIPTION).
STANDARD PROCEDURE - TIRE LEAK
REPAIRING
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 22). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before attempting to dis-
mount the tire from the wheel.Use a lubricant
such as a mild soap solution when dismounting
or mounting tire.Use tools free of burrs or sharp
edges which could damage the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and progressively tighten
the 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
Fig. 20 Under Inflation Wear
1 - THIN TIRE TREAD AREAS
Fig. 21 Over Inflation Wear
1 - THIN TIRE TREAD AREA
Fig. 22 Tire Repair Area
1 - REPAIRABLE AREA
22 - 12 TIRES/WHEELSRS
TIRES (Continued)

CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Care must be taken in the selection of tire and
wheel cleaning chemicals and equipment to prevent
damage to the wheels. Any of the ªDO NOT USEº
items listed below WILL damage chrome plated and
painted aluminum wheels.
DO NOT USE:
²any abrasive metal cleaner
²any abrasive cleaning pad or brush
²any cleaner that contains an acid (this will
immediately react with and discolor the chromium
surface)
²chrome polish (unless it is buffed off immedi-
ately after application)
²oven cleaner
²a car wash that uses carbide-tipped wheel clean-
ing brushes
SPECIFICATIONS
WHEEL
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Wheel Mounting (Lug)
Nut Hex Size19 mm
Wheel Mounting Stud
SizeM12 x 1.5 mm
TORQUE SPECIFICATIONS
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Wheel Mounting (Lug ) Nut 135 100 Ð
WHEEL COVER
DESCRIPTION
This vehicle uses a bolt-on type wheel cover (Fig.
25).
This bolt-on wheel cover cannot be removed from
the wheel until three of the five wheel mounting nuts
shown are removed (Fig. 25). The bolt-on wheel cover
can then be removed with the remaining two wheel
nuts tightened in place.
REMOVAL
(1) Noting the location of the valve stem in rela-
tionship to the wheel mounting nuts, remove the
three wheel mounting nuts securing the wheel cover
to the wheel and hub (Fig. 25).
CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
(2) Grasp the wheel cover at the edges in line with
the remaining installed wheel nuts and pull straight
outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
nuts, removing the wheel cover from the wheel.
INSTALLATION
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
wheel cover (Fig. 26).
(1) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 27).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 27).
This will hold the wheel cover in place.
Fig. 25 Nuts Securing Wheel Cover
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
22 - 14 TIRES/WHEELSRS
WHEELS (Continued)

(2) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 25).
(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 28). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
WHEEL MOUNTING STUDS -
FRONT
REMOVAL
CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs MUST NOT be hammered out of the hub
flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the two adapter mounting bolts secur-
ing both the disc brake caliper adapter to the steer-
ing knuckle (Fig. 29).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 29).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 29).
(6) On the wheel mounting stud to be removed,
install a wheel mounting (lug) nut far enough so the
threads on the stud are even with end of nut. Install
Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 30).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
Fig. 26 Two Wheel Mounting Nuts Installed
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 27 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 28 Nut Tightening Sequence
RSTIRES/WHEELS22-15
WHEEL COVER (Continued)