common rail CHRYSLER VOYAGER 2004 Service Manual

LEFT MID READING LAMP (PREMIUM/LUXURY) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3 M27 20YL/LB READING LAMPS DRIVER
LEFT PARK LAMP (EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z343 16BR GROUND
2 L77 16BK FUSED PARK LAMP RELAY OUTPUT (LEFT)
LEFT POWER MIRROR - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 P171 20TN/YL (EXPORT) LEFT FOLDING MIRROR UNFOLD DRIVER
2 P112 22TN/OR (EXCEPT EXPORT/
MEMORY)MIRROR B(+)
3 P114 22TN/WT (EXCEPT EXPORT/
MEMORY)MIRROR B(-)
4 P65 20TN/VT (MEMORY) LEFT MIRROR HORIZONTAL POSITION SIGNAL
5 P69 20TN/WT (MEMORY) LEFT MIRROR SENSOR GROUND
6 P64 20TN (MEMORY) LEFT MIRROR VERTICAL POSITION SIGNAL
7 P159 20TN/DG (LHD EXPORT) DRIVER FOLDING MIRROR FOLD DRIVER
7 P160 20TN/LG (RHD) PASSENGER FOLDING MIRROR RELAY OUTPUT
8 Z215 22BK/LG GROUND
9 C16 20DB/GY (HEATED MIRRORS) FUSED DEFOGGER RELAY OUTPUT
10 P73 20TN/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P71 20TN/DG LEFT MIRROR UP DRIVER
12 P75 20TN/LG LEFT MIRROR LEFT DRIVER
LEFT REAR LAMP ASSEMBLY - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 L63 18WT/DG (EXCEPT EXPORT) LEFT REAR TURN SIGNAL DRIVER
1 Z363 18BK/DG (EXPORT) GROUND
2 L63 18WT/DG (EXPORT) LEFT REAR TURN SIGNAL DRIVER
3 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
3 L77 18WT/BR (EXCEPT EXPORT) FUSED PARK LAMP RELAY OUTPUT (LEFT)
3 L50 18WT/TN (GAS EXPORT) BRAKE LAMP SWITCH OUTPUT
4 L1 18WT/LG (EXCEPT TRAILER TOW) BACK-UP LAMP FEED
4 L1 18WT/BR (TRAILER TOW) BACK-UP LAMP FEED
5 Z363 18BK/DG (EXCEPT EXPORT) GROUND
5 L38 20WT/YL (EXPORT) REAR FOG LAMP SWITCH OUTPUT
6 L77 18WT/BR (EXPORT) FUSED PARK LAMP RELAY OUTPUT (LEFT)
RS8W-80 CONNECTOR PIN-OUTS8W-80-91

T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION.........................21
OPERATION...........................24
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES....................30
REMOVAL.............................31
DISASSEMBLY.........................35
ASSEMBLY............................42
INSTALLATION.........................51
SPECIFICATIONS - T850 MANUAL
TRANSAXLE.........................56
SPECIAL TOOLS - T850 TRANSAXLE........58
AXLE SEALS
REMOVAL.............................61
INSTALLATION.........................61
BACK-UP LAMP SWITCH
REMOVAL.............................62
INSTALLATION.........................62
DIFFERENTIAL
DESCRIPTION.........................62
OPERATION...........................62
DISASSEMBLY.........................62
ASSEMBLY............................66
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE............................69
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY...........................70
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK.............................71
STANDARD PROCEDURE - FLUID DRAIN
AND FILL............................71
GEARSHIFT BOOT
REMOVAL.............................72
INSTALLATION.........................73GEARSHIFT CABLE - CROSSOVER
REMOVAL.............................73
INSTALLATION.........................76
ADJUSTMENTS
ADJUSTMENT........................79
GEARSHIFT CABLE - SELECTOR
REMOVAL.............................81
INSTALLATION.........................84
GEARSHIFT KNOB
REMOVAL.............................87
INSTALLATION.........................87
GEARSHIFT MECHANISM
REMOVAL.............................87
INSTALLATION.........................89
INPUT SHAFT
DESCRIPTION.........................93
DISASSEMBLY.........................93
ASSEMBLY............................96
INTERMEDIATE SHAFT
DESCRIPTION........................100
DISASSEMBLY........................100
ASSEMBLY...........................107
SHIFT COVER
DESCRIPTION........................113
SHIFT FORK AND SHAFT
DESCRIPTION........................113
SYNCHRONIZER
DESCRIPTION........................114
DISASSEMBLY........................114
CLEANING
CLEAN.............................114
INSPECTION
INSPECT...........................114
ASSEMBLY...........................114
VEHICLE SPEED SENSOR
REMOVAL............................115
INSTALLATION........................115
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.
RST850 MANUAL TRANSAXLE21-21