service CHRYSLER VOYAGER 2001 Service Manual

INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 236) is part
of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated pinion gear, and consists of the following com-
ponents:
²Intermediate Mainshaft
²1st Speed Gear
²2nd Speed Gear
²3/4 Cluster Gear
²5th Speed Gear
²Reverse Gear
²1/2 Synchronizer
²5/R Synchronizer
The intermediate shaft is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.DISASSEMBLY
CAUTION: Do not re-use snap rings when servicing
the intermediate shaft assembly. Discard upon dis-
assembly and install new ones provided with avail-
able snap ring service kit.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear.
(2) Install 8486-4 button to intermediate shaft.
Using arbor press ram, press reverse gear and inter-
mediate roller bearing off of shaft, while holding
remaining assembly with hand (Fig. 237).
Fig. 236 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
RGT850 MANUAL TRANSAXLE21a-81

ASSEMBLY
NOTE: Do not re-use snap rings when servicing the
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.NOTE: When installing 1/2 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 261) for intermediate shaft
assembly reference.
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
Fig. 261
21a - 88 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

SHIFT FORK AND SHAFT
DESCRIPTION
The T850 utilizes a unique shift fork and shaft
arrangement consisting of three shift forks and two
shafts as shown in (Fig. 285). This system is oper-
ated by the shift cover assembly, which combined
with a unique gearshift cable design, offers a higher
mechanical advantage over traditional shift systems.
This arrangement results in less friction and lower
shift cable loads for smoother, more positive opera-
tion. The shift fork assemblies are constructed of
brass, float about the shafts with the aid of needle
bearings, and are serviced only as fork/bearing
assemblies.
SYNCHRONIZER
DESCRIPTION
The T850 transaxle uses two styles of synchronizer
assemblies; a conventional single-cone style is used
for the 5th/Reverse and 3rd/4th applications (Fig.
286), and a dual-cone style for the 1st/2nd gear appli-
cation (Fig. 287).
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ASSEMBLY
(1) Position synchronizer hub onto work bench.
Hub is non-directional.
Fig. 285 Shift Fork/Shaft Components
1 - 5/R FORK
2 - SHAFT/LINK ASSEMBLY
3 - LINK
4 - 3/4 FORK
5 - 1/2 FORK
Fig. 286 3/4-5/R Synchronizer Assembly
1 - SLEEVE
2 - HUB
3 - BLOCKER RING (2)
4 - SPRING (3)
5 - KEY (3)
6 - BALL (3)
RGT850 MANUAL TRANSAXLE21a-95

CLEANING - TIRES
Before delivery of a vehicle, remove the protective
coating on the tires with white sidewalls or raised
white letters. To remove the protective coating, apply
warm water and let it soak for a few minutes. After-
wards, scrub the coating away with a soft bristle
brush. Steam cleaning may also be used to remove
the coating.
CAUTION: DO NOT use gasoline, mineral oil, oil-
based solvent or a wire brush for cleaning.
WHEELS
DESCRIPTION - WHEEL
Original equipment wheels are designed for proper
operation at all loads up to the specified maximum
vehicle capacity.
All models use either steel or aluminum drop-cen-
ter wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety
humps (Fig. 23). Initial inflation of the tires forces
the bead over these raised sections. In case of air
loss, the safety humps hold the tire in position on the
wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights to fit on the flange of the rim (Fig. 24).
When wheel alignment is necessary on a vehicle
with cast aluminum wheels, special wheel clamps are
required to avoid damage to the wheel's finish.The wheel studs and nuts are designed for specific
wheel applications and must be replaced with equiv-
alent parts.
All aluminum wheels have wheel mounting (lug)
nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive runout
²Dents, cracks or irregular bends
²Damaged wheel stud (lug) holes
²Air Leaks
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged, an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
Fig. 23 Safety Rim
1 - TIRE
2 - WELL
3 - SAFETY HUMPS
4 - FLANGE
Fig. 24 Styled Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - STYLED WHEEL WEIGHT
RSTIRES/WHEELS22-13
TIRES (Continued)

Before removing the glass, check the availability of
replacement components.
SEATS
Seat modules are made up of a seat frame, seat
cushion, seat back cushion, a covering material, and
the electrical components used for power operation, if
equipped. Some seat systems also contain seat belt
components and supplemental restraint systems.
Seat assemblies transport the occupants in comfort
and safety. Seat assemblies also help position occu-
pants correctly in the event of airbag deployment.
Seat cushions, coverings, and electrical components
are serviceable. Refer to the appropriate group in
this manual.
EXTERIOR COMPONENTS
Exterior sheet metal components make up the
exterior of the vehicle. Some exterior metal systems
are welded assemblies, such as doors and hoods.
Some exterior trim items are made of composite.
The exterior is finished in various metal stampings
and composite moldings. These assemblies give the
vehicle a finished appearance and protect the occu-
pants from the elements. Some components are part
of the energy absorbing system used to protect the
occupants in collisions. The exterior sheet metal is
repairable and adjustable for fit and finish. Welded
and bonded component systems are adjustable as a
system. Trim components made of composite are
stamped with the type of material used.
DaimlerChrysler uses various fasteners to retain
trim items. At times, it is not possible to remove trim
items without damaging the fastener. If it is not pos-
sible to remove an item without damaging a compo-
nent, cut or break the fasteners and use new ones
when installing the component.
SAFETY PRECAUTIONS AND WARNINGS
WARNING:
EYE PROTECTION SHOULD BE USED WHEN SER-
VICING GLASS COMPONENTS. PERSONAL INJURY
CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL BASED CLEANING SOLVENTS.
PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT
IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION:
When holes must be drilled or punched in an innerbody panel, verify depth of space to the outer body
panel, electrical wiring, or other components. Dam-
age to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative battery cable clamp when
servicing electrical components that are live when
the ignition is OFF. Damage to electrical system can
result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
23 - 2 BODYRS
BODY (Continued)

(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protectionagainst rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.Fig. 16 COVER MESH WITH EPOXY
1 - EPOXY
2 - MESH
3 - PATCH
4 - SPREADER
RSBODY23-9
BODY (Continued)

LUBRICANT USAGE
COMPONENT SERVICE INTERVAL LUBRICANT
Door Hinges - Hinge Pin and Pivot
Contact AreasAs Required Engine Oil
Hood Hingers - Pivot Points As Required Engine Oil
Lifgate Hinges As Required Engine Oil
Door Check Straps As Required Spray white lube (3)
Door Latches As Required Multi-Purpose Grease (Water
Resistant) (1)
Lifgate Latches As Required Spray white lube (3)
Lifgate Prop Pivots As Required Spray white lube (3)
Ash Receiver As Required Spray white lube (3)
Fuel Filler Door Remote Control
Latch MechanismAs Required Spray white lube (3)
Parking Brake Mechanism As Required Spray white lube (3)
Sliding Seat Tracks As Required Spray white lube (3)
All Other Hood Mechanisms As Required Multipurpose Grease (2)
Door Lock Cylinders As Required Lock Cylinder Lubricant (4)
Lifgate Lock Cylinder As Required Lock Cylinder Lubricant (4)
Sliding Door Upper Track As Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Sliding Door Center Track Leading
EdgeAs Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Sliding Door Lower Track Leading
EdgeAs Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Window System Components
(Regulators, tracks, links, channel
areas Ð except glass run
weatherstrips and felt lubricator, if
equipped.)As Required Spray white lube (3)
1 MOPARž Wheel Bearing Grease (High Temperature)
2 MOPARž Multi-Mileage Lubricant or equivalent
3 MOPARž Spray white lube or equivalent
4 MOPARž Lock Cylinder Lubricant or equivalent
23 - 10 BODYRS
BODY (Continued)

(2) Install bolt attaching armrest to seat back.
Tighten bolt to 29N´m (21 ft. lbs.) torque.
(3) Install side cap into the side of the armrest.
CENTER ARMREST 3
PASSENGER BENCH
REMOVAL
(1) Remove screws attaching the plastic grocery
bag retainer. (Refer to 23 - BODY/SEATS/PLASTIC
GROCERY BAG RETAINER - REMOVAL).
(2) Remove seat back rear cover.
(3) Remove E-clip from pivot post.
(4) Remove pivot post.
(5) Remove armrest.
(6) Remove pivot bushings.
INSTALLATION
(1) Install pivot bushings.
(2) Place armrest in position.
(3) Install pivot post.
(4) Install E-clip to pivot post.
(5) Install seat back rear cover.(6) Install screws attaching the plastic grocery bag
retainer. (Refer to 23 - BODY/SEATS/PLASTIC GRO-
CERY BAG RETAINER - INSTALLATION).
FRONT SEAT
REMOVAL
(1) From under vehicle, remove nuts attaching
front seat risers to the floor.
(2) Remove seat and riser from floor (Fig. 14).
(3) Tip seat rearward and disconnect wire connec-
tors from body harness, if equipped.
(4) Remove seat from vehicle.
INSTALLATION
(1) Place seat into position
(2) Tip seat rearward and connect wire connectors
to body harness, if equipped.
(3) Place seat and riser into floor.
(4) From under vehicle, install nuts attaching
front seat risers to the floor. Tighten nuts to 60 N´m
(44 ft. lbs.) torque.
FRONT SEATBACK
REMOVAL
NOTE: On front seats equipped with side air bags,
the seatback is serviced as an assembly.
(1) Remove head rest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - REMOVAL).
Fig. 13 Armrest
1 - SEAT BACK
2 - ARMREST
3 - SHOULDER BOLT
4 - CAP
5 - WASHER
6 - STOP SCREW
Fig. 14 Front Seat
1 - FRONT SEAT
2 - CONNECTORS
3 - B-PILLAR
RSSEATS23 - 227
ARMREST (Continued)

(2) Install the top screws.
FRONT SEATBACK COVER
REMOVAL
NOTE: On vehicles equipped with seat side air bags
the seat cover is NOT serviceable. The seat back is
serviced as an assembly. (Refer to 23 - BODY/
SEATS/SEAT BACK - REMOVAL).
(1) Remove the seat back. (Refer to 23 - BODY/
SEATS/FRONT SEATBACK - REMOVAL).
(2) Unclip J-straps as necessary.
(3) Remove seat back cover from seat back cushion
and frame assembly.
INSTALLATION
NOTE: On vehicles equipped with seat side air bags
the seat cover is NOT serviceable. The seat back is
serviced as an assembly only. (Refer to 23 - BODY/
SEATS/SEAT BACK - INSTALLATION).
(1) Fit seat cover onto seat back cushion and
frame assembly.
(2) Connect the J-straps.
(3) Install the seat back. (Refer to 23 - BODY/
SEATS/FRONT SEATBACK - INSTALLATION).
FRONT/QUAD SEAT CUSHION
REMOVAL
(1) Remove seat cushion side covers, and leave
connector connected, if equipped. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL).
(2) On quad buckets, remove the seat side shield
and cup holder. (Refer to 23 - BODY/SEATS/SEAT
SIDE SHIELD/QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - REMOVAL) and (Refer to
23 - BODY/SEATS/QUAD BUCKET SEAT SIDE
SHIELD - NO CUP HOLDER - REMOVAL).
(3) Remove seat track front and rear covers if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - REMOVAL) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
REMOVAL).
(4) If equipped, open stowage bin to access front
pan bolts.
(5) Remove bolts attaching seat cushion pan to
seat track.
(6) Disconnect wire connectors, if equipment.
(7) Remove seat cushion from seat.
(8) Disengage J-strap retainers holding seat cover
to cushion.
(9) Remove seat cushion pan from cover and pad.
INSTALLATION
(1) Place seat cushion cover in position on seat
cushion.
(2) Engage J-strap retainers to hold seat cover to
cushion.
(3) Place seat cushion in position on seat.
(4) Connect wire connectors, if equipment.
(5) Install bolts attaching seat cushion to seat
track. Tighten bolts to 28.5 N´m (21 ft. lbs.) torque.
(6) If equipped, close stowage bin.
(7) Install seat track front and rear covers, if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - INSTALLATION) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
INSTALLATION).
(8) Install the quad seat side shield and cup holder
if equipped. (Refer to 23 - BODY/SEATS/QUAD
BUCKET SEAT SIDE SHIELD/CUP HOLDER -
INSTALLATION) and (Refer to 23 - BODY/SEATS/
QUAD BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER - INSTALLATION).
(9) Install seat cushion side covers. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION).
Fig. 17 FRONT SEATBACK PANEL - TYPICAL
1 - SCREWS
2 - SEAT BACK PANEL
3 - SEAT BACK
RSSEATS23 - 229
FRONT SEATBACK PANEL (Continued)

(4) Install seat into vehicle. Tighten fasteners to
54 N´m (40 ft. lbs.) torque. (Refer to 23 - BODY/
SEATS/FRONT SEAT - INSTALLATION).
FRONT SEAT TRACK POWER
ADJUSTER
REMOVAL
The power seat track and motors are serviced as
an assembly.
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL).
(2) Remove seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - REMOV-
AL).
(3) Remove nut attaching recliner to seat back
frame.
(4) Remove bolts attaching seat back frame to seat
track.
(5) Remove stud on seat back frame from recliner.
(6) Remove seat back.
(7) If power seat track is being replaced, transfer
power recliner, wire harness and trim covers to
replacement seat track.
INSTALLATION
The power seat track and motors are serviced as
an assembly.
(1) Install wire harness.
(2) Place seat back in position.
(3) Insert stud on seat back frame into recliner.
(4) Install bolts to hold seat back frame to seat
track.
(5) Install nut attaching recliner to seat back
frame.
(6) Install seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - INSTAL-
LATION).
(7) Install seat in vehicle. Tighten fasteners to 60
N´m (44 ft. lbs.) torque. (Refer to 23 - BODY/SEATS/
FRONT SEAT - INSTALLATION).
FRONT SEAT TRACK MANUAL
ADJUSTER
REMOVAL
(1) Remove seat from vehicle. (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL).
(2) Remove seat cushion. (Refer to 23 - BODY/
SEATS/FRONT/QUAD SEAT CUSHION - REMOV-
AL).(3) Remove riser. (Refer to 23 - BODY/SEATS/
FRONT SEAT RISER - MANUAL TRACK - REMOV-
AL).
(4) Remove bolt attaching seat back frame to seat
track (Fig. 21).
(5) Remove seat track from seat adjuster handle
(Fig. 22).
(6) Remove seat track from seat.
INSTALLATION
(1) Place seat track in position on seat.
(2) Place adjuster handle in position on seat track
(Fig. 22).
(3) Insert stud on seat back frame into recliner.
Fig. 21 FRONT SEAT TRACK - MANUAL
1 - SHOULDER BOLT
2 - RECLINER
3 - MANUAL SEAT TRACK
Fig. 22 FRONT SEAT TRACK ADJUSTER HANDLE
1 - RECLINER
2 - SEAT ADJUSTER HANDLE
3 - MANUAL SEAT TRACK
RSSEATS23 - 231
FRONT SEAT RISER - MANUAL TRACK (Continued)