lock CHRYSLER VOYAGER 2004 Service Manual

(9) Remove 3/4 synchronizer snap ring (Fig. 8).
Discard and replace with new snap ring upon assem-
bly.
(10) Remove 3/4 synchronizer (Fig. 9). (11) Remove 3rd gear blocker ring (Fig. 10).
(12) Remove 3rd gear and needle bearing (Fig. 11)
(Fig. 12).
(13) Inspect third gear thrust washer for signs of
excessive wear. To replace, drive off of input shaft
with suitable drift and hammer.
Fig. 8 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 9 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 10 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 11 3rd Gear Removal/Installation
1 - 3RD GEAR
2 - NEEDLE BEARING
21s - 4 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)

(3) Install 3rd gear and needle bearing (Fig. 14)
(Fig. 15). (4) Install 3rd gear blocker ring (Fig. 16).
(5) Install 3/4 synchronizer (Fig. 17).
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.
Fig. 14 3rd Gear Needle Bearing Removal/ Installation
1 - 3RD GEAR NEEDLE BEARING
2 - THRUST WASHER
Fig. 15 3rd Gear Removal/Installation
1 - 3RD GEAR
2 - NEEDLE BEARING
Fig. 16 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 17 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
21s - 6 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)

(6) InstallNEW3/4 synchronizer snap ring (Fig.
18).
(7) Install 4th gear blocker ring (Fig. 19). (8) Install 4th gear and needle bearing (Fig. 20)
(Fig. 21).
Fig. 18 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 19 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 20 4th Gear Needle Bearing Removal/ Installation
1 - 4TH GEAR NEEDLE BEARING
Fig. 21 4th Gear Removal/Installation
1 - 4TH GEAR
2 - NEEDLE BEARING
RS T850 MANUAL TRANSAXLE21s-7
INPUT SHAFT (Continued)

²1/2 Synchronizer
² 5/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.
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. 28). (3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 29).
(5) Remove 5/R synchro snap ring (Fig. 30).
Fig. 28 Bearing and Reverse Gear Removal
1 - ARBOR PRESS RAM
2 - ADAPTER
3 - SEALED ROLLER BEARING
4 - REVERSE GEAR
5 - BEARING SPLITTER P-334
Fig. 29 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 30 5/R Synchro Snap Ring
1 - SNAP RING
21s - 10 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(6) Remove 5/R synchro (Fig. 31).
(7) Remove 5th gear blocker ring (Fig. 32).(8) Remove 5th gear and needle bearing (Fig. 33)
(Fig. 34).
Fig. 31 5/R Synchronizer
1 - 5/R SYNCHRO ASSEMBLY
Fig. 32 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 33 5th Gear Removal/Installation
1 - 5TH GEAR
2 - NEEDLE BEARING
Fig. 34 5th Gear Needle Bearing Removal/ Installation
1 - 5TH GEAR NEEDLE BEARING
RS T850 MANUAL TRANSAXLE21s-11
INTERMEDIATE SHAFT (Continued)

(15) Remove 2nd gear friction cone (Fig. 43).
(16) Remove 2nd Gear outer blocker ring (Fig. 44).(17) Remove 1/2 synchro snap ring (Fig. 45).
(18) Remove 1/2 synchro from shaft (Fig. 46).
Fig. 43 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 44 2nd Gear Outer Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 45 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 46 1/2 Synchronizer
1 - 1/2 SYNCHRONIZER
21s - 14 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(19) Remove 1st gear blocker ring (Fig. 47).
(20) Remove 1st gear friction cone (Fig. 48).(21) Remove 1st gear reactor ring (Fig. 49).
(22) Remove 1st gear from shaft (Fig. 50).
Fig. 47 1st Gear Blocker Ring
1 - 1ST GEAR BLOCKER RING
Fig. 48 1st Gear Friction Cone
1 - 1ST GEAR FRICTION CONE
Fig. 49 1st Gear Reactor Ring
1 - 1ST GEAR REACTOR RING
Fig. 50 1st Gear Removal
1 - 1ST GEAR
RS
T850 MANUAL TRANSAXLE21s-15
INTERMEDIATE SHAFT (Continued)

(6) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 61).
(7) Install intermediate shaft to synchro assembly
on fixture (Fig. 62). When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal. Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture. (8) Install NEW1/2 synchro snap ring (Fig. 63).
Fig. 61 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
Fig. 62 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 63 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
RS T850 MANUAL TRANSAXLE21s-19
INTERMEDIATE SHAFT (Continued)

(9) Install 2nd gear blocker ring (Fig. 64).
(10) Install 2nd gear friction cone (Fig. 65).(11) Install 2nd gear reactor ring (Fig. 66).
(12) Install 2nd gear and needle bearing to inter-
mediate shaft (Fig. 67) (Fig. 68).
Fig. 64 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 65 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 66 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 67 2nd Gear Removal/Installation
1 - 2ND GEAR
2 - NEEDLE BEARING
21s - 20 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(16) Install 5th gear blocker ring to synchronizer
(Fig. 73). (17) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 74). When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
(18) Install NEW5/R synchro snap ring (Fig. 75).
Fig. 72 5th Gear Needle Bearing Removal/
Installation
1 - 5TH GEAR NEEDLE BEARING
Fig. 73 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 74 Install 5/R Synchro and 5th Blocker Ring to 5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
Fig. 75 5/R Synchro Snap Ring
1 - SNAP RING
21s - 22 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)