differential CHRYSLER VOYAGER 2001 Manual Online

(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e) If the turning torque was too high when mea-
sured, install a 0.05 mm (0.002 inch) thinner shim.
If the turning torque is was too low, install a 0.05
mm (0.002 inch) thicker shim. Repeat until 5-18
inch-pounds turning torque is obtained. Oil Baffle
is not required to be installed when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARž Silicone Rubber Adhesive
Sealant and torque bolts to 28 N´m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 213).The turning torque should be within
5-18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Fig. 212 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
Fig. 213 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
21 - 244 AUTOMATIC - 41TERS
FINAL DRIVE (Continued)

DIFFERENTIAL BEARING SHIM CHART
PART NUMBER SHIM THICKNESS
MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A.
(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer
using Miller Special Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) Install the bearing retainer into the case.
Torque bolts to 28 N´m (250 in. lbs.).
(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.
(6)
Rotate the differential at least one full revolution
to ensure the tapered roller bearings are fully seated.
(7)Attach a dial indicator to the case and zero the
dial. Place the tip on the end of Special Tool L-4436-A.
(8) Place a large screwdriver to each side of the
ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.(9) Using the end play measurement that was
determined, add 0.18mm (0.007 inch). This should
give you between 5-18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.
(10) Remove the differential bearing retainer.
Remove the bearing cup.
(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with Moparž Silicone
Rubber Adhesive Sealant. Torque bolts to 28 N´m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
of the differential (Fig. 213). The turning torque
should be between 5-18 inch-pounds.
NOTE: If turning torque is too high install a 0.05mm
(0.002 inch) thicker shim. If the turning torque is too
low, install a 0.05mm (0.002 inch) thinner shim.
Repeat until 5-18 inch-pounds of turning torque is
obtained.
RSAUTOMATIC - 41TE21 - 245
FINAL DRIVE (Continued)

T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page
T850 MANUAL TRANSAXLE.................1
T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION............................2
OPERATION.............................4
DIAGNOSIS AND TESTING.................11
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES.....................11
REMOVAL..............................11
DISASSEMBLY...........................17
ASSEMBLY.............................22
INSTALLATION...........................31
SPECIFICATIONS........................37
SPECIAL TOOLS.........................39
AXLE SEALS
REMOVAL..............................42
INSTALLATION...........................42
BACK-UP LAMP SWITCH
REMOVAL..............................43
INSTALLATION...........................43
DIFFERENTIAL
DESCRIPTION...........................43
OPERATION.............................43
DISASSEMBLY...........................44
ASSEMBLY.............................47
ADJUSTMENTS..........................50
FLUID
STANDARD PROCEDURE..................52
STANDARD PROCEDURE - FLUID LEVEL
CHECK...............................52
STANDARD PROCEDURE - FLUID DRAIN
AND FILL.............................53
GEARSHIFT BOOT
REMOVAL..............................53
INSTALLATION...........................53
GEARSHIFT CABLE - CROSSOVER
REMOVAL..............................54INSTALLATION...........................56
ADJUSTMENTS..........................60
GEARSHIFT CABLE - SELECTOR
REMOVAL..............................61
INSTALLATION...........................64
GEARSHIFT KNOB
REMOVAL..............................67
INSTALLATION...........................67
GEARSHIFT MECHANISM
REMOVAL..............................68
INSTALLATION...........................70
INPUT SHAFT
DESCRIPTION...........................73
DISASSEMBLY...........................74
ASSEMBLY.............................77
INTERMEDIATE SHAFT
DESCRIPTION...........................81
DISASSEMBLY...........................81
ASSEMBLY.............................88
SHIFT COVER
DESCRIPTION...........................94
SHIFT FORK AND SHAFT
DESCRIPTION...........................95
SYNCHRONIZER
DESCRIPTION...........................95
DISASSEMBLY...........................95
CLEANING..............................95
INSPECTION............................95
ASSEMBLY.............................95
VEHICLE SPEED SENSOR
REMOVAL..............................96
INSTALLATION...........................96
RGT850 MANUAL TRANSAXLE21a-1

T850 MANUAL TRANSAXLE
DESCRIPTION
Fig. 1 NV T850 Transaxle
1 - 3RD GEAR (SPEED) 9 - INTERMEDIATE SHAFT BEARING
(SEALED BALL)17 - 1/2 SYNCHRONIZER
2 - 3/4 SYNCHRONIZER 10 - REVERSE GEAR 18 - 1ST GEAR (SPEED)
3 - 3/4 SHIFT FORK 11 - 5/R SYNCHRONIZER 19 - DIFFERENTIAL ASSEMBLY
4 - 4TH GEAR (SPEED) 12 - 5/R SHIFT FORK 20 - EXTENSION HOUSING
5 - 5TH GEAR (INPUT) 13 - 5TH GEAR (SPEED) 21 - INTERMEDIATE SHAFT BEARING
(CAGED ROLLER)
6 - REVERSE IDLER GEAR 14 - 3/4 CLUSTER GEAR 22 - INTERMEDIATE SHAFT
7 - END COVER, REAR 15 - 2ND GEAR (SPEED) 23 - INPUT SHAFT
8 - INPUT SHAFT BEARING (SEALED
BALL)16 - 1/2 SHIFT FORK 24 - CASE
25 - INPUT SHAFT BEARING (ROLLER)
21a - 2 T850 MANUAL TRANSAXLERG

OPERATION
NEUTRAL
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. Since
no synchronizers are engaged on either the input orintermediate shafts, power is not transmitted to the
intermediate shaft and the differential does not turn
(Fig. 3).
Fig. 3 Neutral Gear Operation
21a - 4 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

1ST GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft first gear is integral to the input shaft,
and is in constant mesh with the intermediate shaft
first speed gear. Because of this constant mesh, the
intermediate shaft first speed gear freewheels untilfirst gear is selected. As the gearshift lever is moved
to the first gear position, the 1-2 fork moves the 1-2
synchronizer sleeve towards first gear on the inter-
mediate shaft. The synchronizer sleeve engages the
first gear clutch teeth, fixing the gear to the interme-
diate shaft, and allowing power to transmit through
the intermediate shaft to the differential (Fig. 4).
Fig. 4 1st Gear Operation
RGT850 MANUAL TRANSAXLE21a-5
T850 MANUAL TRANSAXLE (Continued)

3RD GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft third speed gear is in constant mesh with
the intermediate shaft 3-4 cluster gear, which is fixed
to the intermediate shaft. Because of this constant
mesh, the input shaft third speed gear freewheelsuntil third gear is selected. As the gearshift lever is
moved to the third gear position, the 3-4 fork moves
the 3-4 synchronizer sleeve towards third gear on the
input shaft. The synchronizer sleeve engages the
third gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 6).
Fig. 6 3rd Gear Operation
RGT850 MANUAL TRANSAXLE21a-7
T850 MANUAL TRANSAXLE (Continued)

5TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fifth gear is pressed on to the input shaft,
and is in constant mesh with the intermediate shaft
fifth speed gear. Because of this constant mesh, the
intermediate shaft fifth speed gear freewheels untilfifth gear is selected. As the gearshift lever is moved
to the fifth gear position, the 5-R fork moves the 5-R
synchronizer sleeve towards the intermediate shaft
fifth speed gear. The synchronizer sleeve engages the
fifth gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 8).
Fig. 8 5th Gear Operation
RGT850 MANUAL TRANSAXLE21a-9
T850 MANUAL TRANSAXLE (Continued)

REVERSE GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft reverse gear is integral to the input
shaft, and is in constant mesh with the reverse idler
gear. The reverse idler gear, which reverses the rota-
tion of the intermediate shaft, is in constant mesh
with the intermediate shaft reverse gear. Because of
this constant mesh, the intermediate shaft reversegear freewheels until reverse gear is selected. As the
gearshift lever is moved to the reverse gear position,
the 5-R fork moves the 5-R synchronizer sleeve
towards the intermediate shaft reverse gear. The
synchronizer sleeve engages the reverse gear clutch
teeth, fixing the gear to the intermediate shaft, and
allowing power to transmit through the intermediate
shaft to the differential (in reverse) (Fig. 9).
Fig. 9 Reverse Gear Operation
21a - 10 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (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)