lock CHRYSLER VOYAGER 2001 Service Manual

(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)

(3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 238).(5) Remove 5/R synchro snap ring (Fig. 239).
(6) Remove 5/R synchro (Fig. 240).
Fig. 237 Bearing and Reverse Gear Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - SEALED ROLLER BEARING
4 - REVERSE GEAR
5 - BEARING SPLITTER P-334
Fig. 238 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 239 5/R Synchro Snap Ring
1 - SNAP RING
Fig. 240 5/R Synchronizer
1 - 5/R SYNCHRO ASSEMBLY
21a - 82 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(7) Remove 5th gear blocker ring (Fig. 241).
(8) Remove 5th gear (Fig. 242).(9) Remove 3/4 cluster gear snap ring (Fig. 243).
(10) Install shaft assembly into fixture 8483, with
split collar 8483-3 oriented chamfer side up (Fig.
244). Place 8483-2 into position with chamfer side up
(Fig. 245).
Fig. 241 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 242 5th Gear
1 - 5th GEAR
Fig. 243 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 244 Fixture 8483
1 - FIXTURE 8483
2 - COLLAR 8483-3
RGT850 MANUAL TRANSAXLE21a-83
INTERMEDIATE SHAFT (Continued)

(14) Remove 2nd gear reactor ring (Fig. 249).
(15) Remove 2nd gear friction cone (Fig. 250).(16) Remove 2nd Gear outer blocker ring (Fig.
251).
(17) Remove 1/2 synchro snap ring (Fig. 252).
Fig. 249 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 250 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 251 2nd Gear Outer Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 252 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
RGT850 MANUAL TRANSAXLE21a-85
INTERMEDIATE SHAFT (Continued)

(18) Remove 1/2 synchro from shaft (Fig. 253).
(19) Remove 1st gear blocker ring (Fig. 254).(20) Remove 1st gear friction cone (Fig. 255).
(21) Remove 1st gear reactor ring (Fig. 256).
Fig. 253 1/2 Synchronizer
1 - 1/2 SYNCHRONIZER
Fig. 254 1st Gear Blocker Ring
1 - 1ST GEAR BLOCKER RING
Fig. 255 1st Gear Friction Cone
1 - 1ST GEAR FRICTION CONE
Fig. 256 1st Gear Reactor Ring
1 - 1ST GEAR REACTOR RING
21a - 86 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 262).
(2) Install intermediate shaft roller bearing snap
ring (Fig. 263).
(3) Install 1st gear roller bearing to intermediate
shaft (Fig. 264).(4) Install 1st gear to intermediate shaft (Fig.
265).
(5) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 266).
(6) Install intermediate shaft to synchro assembly
on fixture (Fig. 267).When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal.Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture.
Fig. 262 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
Fig. 263 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 264 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 265 1st Gear Installation
1 - 1ST GEAR
RGT850 MANUAL TRANSAXLE21a-89
INTERMEDIATE SHAFT (Continued)

(7) InstallNEW1/2 synchro snap ring (Fig. 268).
(8) Install 2nd gear blocker ring (Fig. 269).
Fig. 266 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
Fig. 267 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 268 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 269 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
21a - 90 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(13) InstallNEW3/4 cluster gear snap ring (Fig.
274).
(14) Install 5th gear to intermediate shaft (Fig.
275).(15) Install 5th gear blocker ring to synchronizer
(Fig. 276).
(16) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 277).When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
Fig. 274 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 275 5th Gear Installation
1 - 5th GEAR
Fig. 276 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 277 Install 5/R Synchro and 5th Blocker Ring to
5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
21a - 92 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(17) InstallNEW5/R synchro snap ring (Fig. 278).
(18) Install reverse gear blocker ring (Fig. 279).
(19) Install reverse gear needle bearing (Fig. 280).
(20) Install reverse gear to intermediate shaft.
(21) Install intermediate shaft sealed roller bear-
ing and thrust washer using installer 8482 (Fig. 281).
Fig. 278 5/R Synchro Snap Ring
1 - SNAP RING
Fig. 279 Reverse Gear Blocker Ring
1 - REVERSE BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 280 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 281 Sealed Roller Bearing Installatiion
1 - ARBOR PRESS
2 - REMOVER/INSTALLER 8482
3 - SEALED ROLLER BEARING
4 - THRUST WASHER
RGT850 MANUAL TRANSAXLE21a-93
INTERMEDIATE SHAFT (Continued)

(22) InstallNEWintermediate shaft sealed bear-
ing snap ring (Fig. 282).
SHIFT COVER
DESCRIPTION
The shift cover assembly (Fig. 283) (Fig. 284) is
operated by the gearshift crossover and selector
cables, and operates the shift fork/shaft system. It
consists of crossover and selector lever mechanisms,
transaxle vent, a main shift selector shaft, and the
5-R blockout mechanism. The shift cover is only ser-
viced as an assembly.
Fig. 282 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
Fig. 283 Shift Lever Identification
1 - SHIFT COVER ASSEMBLY
2 - VENT
3 - CROSSOVER LEVER
4 - SELECTOR LEVER
Fig. 284 Shift Cover Assembly Components
1 - SHAFT
2 - 5-R BLOCKOUT PIN/CAM
3 - SHIFT SELECTOR
4 - SHIFT BLOCKER
5 - SELECTOR LEVER/DETENT
21a - 94 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)