CHRYSLER VOYAGER 2002 Service Manual

(1) Install input shaft into fixture 8487.
(2) Install thrust washer if removed upon disas-
sembly.
(3) Install 3rd gear (Fig. 216).
(4) Install 3rd gear blocker ring (Fig. 217).(5) Install 3/4 synchronizer (Fig. 218).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 journal.
(6) InstallNEW3/4 synchronizer snap ring (Fig.
219).
Fig. 216 3rd Gear Removal/Installation
1 - 3RD GEAR
Fig. 217 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 218 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 219 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
21 - 384 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)
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(7) Install 4th gear blocker ring (Fig. 220).
(8) Install 4th gear (Fig. 221).
(9) Install 5th gear and press into position using
installer 8481 (Fig. 222).
(10) InstallNEW5th gear nut and torque to 200
N´m (148 ft. lbs.) using wrench 8478 (Fig. 223).
Fig. 220 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 221 4th Gear Removal/Installation
1 - 4th GEAR
Fig. 222 5th Gear Installation
1 - ARBOR PRESS RAM
2 - INSTALLER 8481
3 - 5TH GEAR
Fig. 223 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
RST850 MANUAL TRANSAXLE21 - 385
INPUT SHAFT (Continued)
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(11) Stake 5th Gear nut as follows:
(a) Install staking tool 8479 to 5th gear nut.
(b) Tighten upper thumb screw by hand (Fig.
224).
(c) Tighten two (2) side thumb screws by hand.
(d) Tighten both staking screws until they bot-
tom on tool body (Fig. 225).
(e) Loosen staking screws and thumb screws.
Remove tool and visually inspect stake (Fig. 226).
NOTE: The input shaft sealed roller bearing and
snap ring do not get installed until transaxle assem-
bly to facilitate installation of the reverse idler gear
mechanism.
Fig. 224 Staking Tool Set-Up
1 - STAKING TOOL 8479
2 - THUMB SCREWS (3)
Fig. 225 Tighten Stake Screws
1 - STAKING TOOL 8479
Fig. 226 5th Gear Nut Stake
1-STAKE
2 - 5TH GEAR NUT
21 - 386 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)
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INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 227) 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.
Fig. 227 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
RST850 MANUAL TRANSAXLE21 - 387
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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. 228).
(3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 229).
(5) Remove 5/R synchro snap ring (Fig. 230).
Fig. 228 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. 229 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 230 5/R Synchro Snap Ring
1 - SNAP RING
21 - 388 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(6) Remove 5/R synchro (Fig. 231).
(7) Remove 5th gear blocker ring (Fig. 232).(8) Remove 5th gear (Fig. 233).
(9) Remove 3/4 cluster gear snap ring (Fig. 234).
Fig. 231 5/R Synchronizer
1 - 5/R SYNCHRO ASSEMBLY
Fig. 232 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 233 5th Gear
1 - 5th GEAR
Fig. 234 3/4 Cluster Gear Snap Ring
1 - SNAP RING
RST850 MANUAL TRANSAXLE21 - 389
INTERMEDIATE SHAFT (Continued)
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(10) Install shaft assembly into fixture 8483, with
split collar 8483-3 oriented chamfer side up (Fig.
235). Place 8483-2 into position with chamfer side up
(Fig. 236).
(11) Using an arbor press, press intermediate shaft
out of 3/4 cluster gear (Fig. 237).
(12) Remove intermediate shaft from fixture and
remove 3/4 cluster gear from shaft (Fig. 238).
Fig. 235 Fixture 8483
1 - FIXTURE 8483
2 - COLLAR 8483-3
Fig. 236 Loading Intermediate Shaft
1 - FIXTURE 8483
1 - 3/4 CLUSTER GEAR
2 - COLLAR 8483-2
Fig. 237 Press Intermediate Shaft Out of 3/4 Cluster
Gear
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - 3/4 CLUSTER GEAR
4 - FIXTURE 8483
Fig. 238 3/4 Cluster Gear
1 - 3/4 CLUSTER GEAR
2 - INTERMEDIATE SHAFT
21 - 390 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(13) Remove 2nd gear from shaft (Fig. 239).
(14) Remove 2nd gear reactor ring (Fig. 240).(15) Remove 2nd gear friction cone (Fig. 241).
(16) Remove 2nd Gear outer blocker ring (Fig.
242).
Fig. 239 2nd Gear Removal
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
Fig. 240 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 241 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 242 2nd Gear Outer Blocker Ring
1 - 2ND GEAR BLOCKER RING
RST850 MANUAL TRANSAXLE21 - 391
INTERMEDIATE SHAFT (Continued)
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(17) Remove 1/2 synchro snap ring (Fig. 243).
(18) Remove 1/2 synchro from shaft (Fig. 244).(19) Remove 1st gear blocker ring (Fig. 245).
(20) Remove 1st gear friction cone (Fig. 246).
Fig. 243 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 244 1/2 Synchronizer
1 - 1/2 SYNCHRONIZER
Fig. 245 1st Gear Blocker Ring
1 - 1ST GEAR BLOCKER RING
Fig. 246 1st Gear Friction Cone
1 - 1ST GEAR FRICTION CONE
21 - 392 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(21) Remove 1st gear reactor ring (Fig. 247).
(22) Remove 1st gear from shaft (Fig. 248).(23) Remove 1st gear needle bearing (Fig. 249).
(24) Remove intermediate shaft roller bearing
snap ring (Fig. 250).
Fig. 247 1st Gear Reactor Ring
1 - 1ST GEAR REACTOR RING
Fig. 248 1st Gear Removal
1 - 1ST GEAR
Fig. 249 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 250 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
RST850 MANUAL TRANSAXLE21 - 393
INTERMEDIATE SHAFT (Continued)
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