CHRYSLER VOYAGER 2002 Service Manual

(14) Install gearshift boot to console (Fig. 182).
Secure with three (3) retainer clips.
(15) Install gearshift knob to gearshift lever (Fig.
183). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(16) Connect battery negative cable.
GEARSHIFT KNOB
REMOVAL
(1) Separate gearshift boot from base of knob.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clockwise (Fig. 184).
INSTALLATION
(1) Install gearshift knob pattern1¤4-turn clock-
wise, press down, and rotate1¤4-turn counter clock-
wise (Fig. 184).
(2) Secure gearshift boot to base of knob.
Fig. 182 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 183 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 184 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21 - 374 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4turn clock-wise (Fig. 185).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 186).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
187).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
188).
Fig. 185 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 186 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 187 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 188 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
RST850 MANUAL TRANSAXLE21 - 375
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(7) Remove center console support bracket (Fig.
189).
(8) Remove crossover cable retainer clip (Fig. 190).(9) Remove crossover cable from gearshift mecha-
nism (Fig. 191).
(10) Remove selector cable retainer clip (Fig. 192).
Fig. 189 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 190 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 191 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 192 Selector Cable Retainer Clip
1 - RETAINER CLIP
21 - 376 T850 MANUAL TRANSAXLERS
GEARSHIFT MECHANISM (Continued)
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(11) Remove selector cable from gearshift mecha-
nism (Fig. 193).
(12) Remove four (4) gearshift mechanism-to-park
brake bracket nuts. Remove gearshift mechanism
from bracket (Fig. 194).INSTALLATION
(1) Install gearshift mechanism to park brake
bracket (Fig. 195). Install and torque nuts to 12 N´m
(108 in. lbs.).
(2) Install selector cable to gearshift mechanism
(Fig. 196). Install retainer clip (Fig. 197).
Fig. 193 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 194 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 195 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 196 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
RST850 MANUAL TRANSAXLE21 - 377
GEARSHIFT MECHANISM (Continued)
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(3) Install crossover cable to gearshift mechanism
(Fig. 198). Install retainer clip (Fig. 199).(4) Adjust crossover cable.
(5) Install center console support bracket (Fig.
200). Torque support bracket-to-gearshift mechanism
screws to 12 N´m (108 in. lbs.).
Fig. 197 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 198 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 199 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 200 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
21 - 378 T850 MANUAL TRANSAXLERS
GEARSHIFT MECHANISM (Continued)
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(6) Install center console assembly (Fig. 201).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(7) Install cupholder plugs (Fig. 202).(8) Install gearshift boot to console (Fig. 203).
Secure with three (3) retainer clips.
(9) Install gearshift knob to gearshift lever (Fig.
204). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 201 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 202 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 203 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 204 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RST850 MANUAL TRANSAXLE21 - 379
GEARSHIFT MECHANISM (Continued)
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INPUT SHAFT
DESCRIPTION
The input shaft assembly (Fig. 205) is part of the
transaxle geartrain, is driven by the clutch assembly,
and consists of the following components:
²Input Mainshaft
²3rd Speed Gear
²4th Speed Gear
²3/4 Synchronizer
²5th Input Gear
The input shaft meshes with the intermediate
shaft, and is supported by a needle bearing at the
front of the transaxle, and a sealed roller bearing at
the rear of the transaxle.
DISASSEMBLY
NOTE: When servicing the input shaft assembly, all
snap rings which are removed MUST be replaced
with new snap rings upon reassembly. The 5th gear
nut must be replaced also.
(1) Invert input shaft assembly and place in fix-
ture 8487.(2) Remove input bearing snap ring (Fig. 206).
Fig. 205 Input Shaft Assembly
1 - INPUT SHAFT 6 - 5TH GEAR NUT
2 - THRUST WASHER 7 - SNAP RING
3 - 3RD GEAR 8 - INPUT BEARING (SEALED)
4 - 4TH GEAR 9 - SNAP RING
5 - 5TH GEAR 10 - 3/4 SYNCHRONIZER
Fig. 206 Input Bearing Snap Ring Removal
1 - SNAP RING
2 - INPUT BEARING
21 - 380 T850 MANUAL TRANSAXLERS
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(3) Remove input bearing. Place input shaft
assembly onto arbor press table, with the input bear-
ing supported by bearing splitter (Fig. 207). Using
adapter 8486-4, press bearing off of shaft, while
helper supports shaft to prevent dropping.
(4) Place input shaft assembly back into fixture
8487. Secure fixture to bench with fasteners, or
secure to bench vise.
NOTE: 5th gear nut is staked to the shaft. If neces-
sary, grind stake area to ease removal, but use care
not to contact gear.
(5) Remove 5th gear nut with wrench 8478 (Fig.
208). Discard nut and use a new one upon assembly.
(6) Remove 5th gear with arbor press and bearing
splitter.
(7) Remove 4th gear (Fig. 209).
Fig. 207 Input Bearing Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - INPUT BEARING
4 - BEARING SPLITTER
Fig. 208 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
Fig. 209 4th Gear Removal/Installation
1 - 4th GEAR
RST850 MANUAL TRANSAXLE21 - 381
INPUT SHAFT (Continued)
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(8) Remove 4th gear blocker ring (Fig. 210).
(9) Remove 3/4 synchronizer snap ring (Fig. 211).
Discard and replace with new snap ring upon assem-
bly.(10) Remove 3/4 synchronizer (Fig. 212).
(11) Remove 3rd gear blocker ring (Fig. 213).
Fig. 210 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 211 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 212 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 213 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
21 - 382 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)
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(12) Remove 3rd gear (Fig. 214). (13) Inspect third gear thrust washer for signs of
excessive wear. To replace, drive off of input shaft
with suitable drift and hammer.
ASSEMBLY
NOTE: When servicing the input shaft assembly, all
snap rings MUST be replaced with new ones upon
assembly. 5th gear nut must also be replaced.
NOTE: When installing 3/4 synchronizer hub to
shaft, make sure to align oil slots on synchronizer
hub face with oil hole in the shaft splined hub jour-
nal.
NOTE: Refer to (Fig. 215) for input shaft assembly
reference.
Fig. 215 Input Shaft Assembly
1 - INPUT SHAFT 6 - 5TH GEAR NUT
2 - THRUST WASHER 7 - SNAP RING
3 - 3RD GEAR 8 - INPUT BEARING (SEALED)
4 - 4TH GEAR 9 - SNAP RING
5 - 5TH GEAR 10 - 3/4 SYNCHRONIZER
Fig. 214 3rd Gear Removal/Installation
1 - 3RD GEAR
RST850 MANUAL TRANSAXLE21 - 383
INPUT SHAFT (Continued)
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