Shift cable CHRYSLER VOYAGER 2002 Manual Online

(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 174).
(8) Install battery, hold-down clamp, and nut (Fig.
175).(9) Install battery thermal shield (Fig. 176).
(10) Install selector cable to gearshift mechanism
(Fig. 177). Install retainer clip (Fig. 178).
Fig. 174 Battery Tray
1 - BATTERY TRAY
Fig. 175 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 176 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 177 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
21 - 372 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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(11) Install center console support bracket (Fig.
179). Torque support bracket-to-gearshift mechanism
screws to 12 N´m (108 in. lbs.).(12) Install center console assembly (Fig. 180).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(13) Install cupholder plugs (Fig. 181).
Fig. 178 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 179 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 180 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 181 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
RST850 MANUAL TRANSAXLE21 - 373
GEARSHIFT CABLE - SELECTOR (Continued)
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(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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(22) InstallNEWintermediate shaft sealed bear-
ing snap ring (Fig. 273).
SHIFT COVER
DESCRIPTION
The shift cover assembly (Fig. 274) (Fig. 275) 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. 274 Shift Lever Identification
1 - SHIFT COVER ASSEMBLY
2 - VENT
3 - CROSSOVER LEVER
4 - SELECTOR LEVER
Fig. 273 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
Fig. 275 Shift Cover Assembly Components
1 - SHAFT
2 - 5-R BLOCKOUT PIN/CAM
3 - SHIFT SELECTOR
4 - SHIFT BLOCKER
5 - SELECTOR LEVER/DETENT
RST850 MANUAL TRANSAXLE21 - 401
INTERMEDIATE SHAFT (Continued)
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SHIFT FORK AND SHAFT
DESCRIPTION
The T850 utilizes a unique shift fork and shaft
arrangement consisting of three shift forks and two
shafts as shown in (Fig. 276). This system is oper-
ated by the shift cover assembly, which combined
with a unique gearshift cable design, offers a higher
mechanical advantage over traditional shift systems.
This arrangement results in less friction and lower
shift cable loads for smoother, more positive opera-
tion. The shift fork assemblies are constructed of
brass, float about the shafts with the aid of needle
bearings, and are serviced only as fork/bearing
assemblies.
SYNCHRONIZER
DESCRIPTION
The T850 transaxle uses two styles of synchronizer
assemblies; a conventional single-cone style is used
for the 5th/Reverse and 3rd/4th applications (Fig.
277), and a dual-cone style for the 1st/2nd gear appli-
cation (Fig. 278).
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
CLEANING
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECTION
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
Fig. 276 Shift Fork/Shaft Components
1 - 5/R FORK
2 - SHAFT/LINK ASSEMBLY
3 - LINK
4 - 3/4 FORK
5 - 1/2 FORK
Fig. 277 3/4-5/R Synchronizer Assembly
1 - SLEEVE
2 - HUB
3 - BLOCKER RING (2)
4 - SPRING (3)
5 - KEY (3)
6 - BALL (3)
21 - 402 T850 MANUAL TRANSAXLERS
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