sensor CHRYSLER VOYAGER 2002 Service Manual

(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 351) (Fig.
352).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the TCM Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)(1) Remove manual shaft seal (Fig. 353).
(2) Remove Transmission Range Sensor retaining
screw (Fig. 354).
Fig. 351 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 352 Valve Body Removal/Installation
1 - VALVE BODY
Fig. 353 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 354 Remove Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
RS41TE AUTOMATIC TRANSAXLE21 - 297
VALVE BODY (Continued)
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(3) Remove Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 355).
(4) Remove 2/4 Accumulator Retaining Plate (Fig.
356).(5) Remove 2/4 Accumulator components as shown
in (Fig. 357).
(6) Remove Valve Body to Transfer Plate screws
(Fig. 358).
Fig. 355 Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 356 2/4 Accumulator Retaining Plate
1 - 2±4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING
Fig. 357 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
Fig. 358 Remove Valve Body to Transfer Plate
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
21 - 298 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(14) Install Manual Shaft/Rooster Comb and
Transmission Range Sensor (Fig. 381).
(15) Make sure Manual Valve control pin is con-
tained within the rooster comb slot (Fig. 382). Install
Transmission Range Sensor retaining screw (Fig.
382) and torque to 5 N´m (45 in. lbs.).(16) Install manual shaft seal (Fig. 383).
INSTALLATION
NOTE: If valve body assembly is being replaced or
reconditioned, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install valve body assembly to transaxle (Fig.
384). Install and torque valve body-to-transaxle case
bolts (Fig. 385) to 12 N´m (105 in. lbs.).
Fig. 381 Install Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 382 Install Transmission Range Sensor
Retaining Screw
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
Fig. 383 Manual Shaft Seal
1 - SEAL
2 - MANUAL SHAFT
Fig. 384 Valve Body Removal/Installation
1 - VALVE BODY
21 - 306 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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(2) Install transaxle oil filter (Fig. 386). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-ant to the oil pan and install (Fig. 387). Torque oil
pan-to-transaxle case bolts (Fig. 388) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 385 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 386 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 387 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 388 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
RS41TE AUTOMATIC TRANSAXLE21 - 307
VALVE BODY (Continued)
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T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION........................308
OPERATION..........................311
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES...................318
REMOVAL............................318
DISASSEMBLY........................323
ASSEMBLY...........................329
INSTALLATION........................338
SPECIFICATIONS - T850 MANUAL
TRANSAXLE........................343
SPECIAL TOOLS - T850 TRANSAXLE.......345
AXLE SEALS
REMOVAL............................348
INSTALLATION........................348
BACK-UP LAMP SWITCH
REMOVAL............................349
INSTALLATION........................349
DIFFERENTIAL
DESCRIPTION........................349
OPERATION..........................349
DISASSEMBLY........................350
ASSEMBLY...........................353
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE...........................356
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY..........................358
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................358
STANDARD PROCEDURE - FLUID DRAIN
AND FILL...........................359
GEARSHIFT BOOT
REMOVAL............................359
INSTALLATION........................360GEARSHIFT CABLE - CROSSOVER
REMOVAL............................360
INSTALLATION........................363
ADJUSTMENTS
ADJUSTMENT.......................366
GEARSHIFT CABLE - SELECTOR
REMOVAL............................368
INSTALLATION........................371
GEARSHIFT KNOB
REMOVAL............................374
INSTALLATION........................374
GEARSHIFT MECHANISM
REMOVAL............................375
INSTALLATION........................377
INPUT SHAFT
DESCRIPTION........................380
DISASSEMBLY........................380
ASSEMBLY...........................383
INTERMEDIATE SHAFT
DESCRIPTION........................387
DISASSEMBLY........................388
ASSEMBLY...........................395
SHIFT COVER
DESCRIPTION........................401
SHIFT FORK AND SHAFT
DESCRIPTION........................402
SYNCHRONIZER
DESCRIPTION........................402
DISASSEMBLY........................402
CLEANING
CLEAN............................402
INSPECTION
INSPECT...........................402
ASSEMBLY...........................403
VEHICLE SPEED SENSOR
REMOVAL............................403
INSTALLATION........................403
T850 MANUAL TRANSAXLE
DESCRIPTION
The NV T850 5-speed transaxle (Fig. 1) is a con-
stant-mesh manual transaxle that is synchronized in
all gear ranges, including reverse.
The transaxle consists of three major sub-assem-
blies: the input shaft, intermediate shaft, and differ-ential assembly. The transaxle shift system consists
of a mechanical shift cover, rails, forks, and cables.
The unique design of this shift system provides a
higher mechanical advantage, resulting in less fric-
tion and lower shift cable loads for smoother, more
positive operation.
21 - 308 T850 MANUAL TRANSAXLERS
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(5) Remove battery tray (Fig. 17). Disconnect bat-
tery temperature sensor.
(6) Remove coolant recovery bottle from bracket.
(7) Remove coolant recovery bottle mounting
bracket (Fig. 18).
(8) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 19).
(9) Remove gearshift cable retaining clips from
mounting bracket (Fig. 19). Remove cables and
secure out of way.(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 20).
Fig. 17 Battery Tray
1 - BATTERY TRAY
Fig. 18 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 19 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 20 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RST850 MANUAL TRANSAXLE21 - 321
T850 MANUAL TRANSAXLE (Continued)
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(14) Connect gearshift cables to shift levers/cover
assembly (Fig. 87). Install cables into position at
mount bracket and secure with retaining clips.
(15) Install coolant recovery bottle bracket (Fig.
88).(16) Install coolant recovery bottle to bracket.
(17) Connect battery temperature sensor and
install battery tray (Fig. 89).
(18) Install battery, hold-down clamp and nut (Fig.
90).
Fig. 87 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 88 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 89 Battery Tray
1 - BATTERY TRAY
Fig. 90 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
21 - 342 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(9) Remove crossover cable from gearshift mecha-
nism (Fig. 137).
(10)2.4L Gas equipped models goto Step 15.
2.5L TD models:Remove battery thermal shield
(Fig. 138).(11) Remove battery hold down nut, clamp, and
battery (Fig. 139).
(12) Remove battery tray (Fig. 140). Disconnect
battery temperature sensor.
Fig. 137 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 138 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 139 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 140 Battery Tray
1 - BATTERY TRAY
21 - 362 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)
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(5)2.4L Gas models goto Step 10. 2.5L TD
Models:Install coolant recovery bottle bracket (Fig.
144).
(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 145).(8) Install battery, hold-down clamp, and nut (Fig.
146).
(9) Install battery thermal shield (Fig. 147).
Fig. 144 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 145 Battery Tray
1 - BATTERY TRAY
Fig. 146 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 147 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
21 - 364 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)
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(10)2.4L Gas models goto Step 15. 2.5L TD
Models:Remove battery thermal shield (Fig. 167).
(11) Remove battery hold down nut, clamp, and
battery (Fig. 168).(12) Remove battery tray (Fig. 169). Disconnect
battery temperature sensor.
(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 170).
Fig. 167 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 168 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 169 Battery Tray
1 - BATTERY TRAY
Fig. 170 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
21 - 370 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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