DODGE TOWN AND COUNTRY 2001 Service Manual

(14) Disconnect back-up lamp switch connector.
(15) Remove structural collar.
(16) Remove modular clutch assembly-to-drive
plate bolts.
(17) Position screw jack and wood block to engine
oil pan.
(18) Remove transmission upper mount through-
bolt from left frame rail.
(19) Lower engine/transaxle assembly on screw
jack.
(20) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 15).
(21) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(22) Remove transaxle from engine.
(23) Inspect modular clutch assembly, clutch
release components, and engine drive plate.
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 13 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 12 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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REMOVAL - 2.5L TD
(1) Raise hood.
(2) Disconnect both battery cables.
(3) Remove battery thermal shield and clutch cable
eyelet (LHD only) (Fig. 16).
(4) Remove battery hold down bolt, clamp, and
battery (Fig. 17).
Fig. 14 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 15 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
Fig. 16 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 17 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
RGT850 MANUAL TRANSAXLE21a-13
T850 MANUAL TRANSAXLE (Continued)
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(5) Remove battery tray (Fig. 18). Disconnect bat-
tery temperature sensor.
(6) Remove coolant recovery bottle from bracket.
(7) Remove coolant recovery bottle mounting
bracket (Fig. 19).
(8) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 20).
(9) Remove gearshift cable retaining clips from
mounting bracket (Fig. 20). Remove cables and
secure out of way.(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 21).
Fig. 18 Battery Tray
1 - BATTERY TRAY
Fig. 19 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 20 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 21 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
21a - 14 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove cradle plate.
(16) Remove front harness retainer and secure
harness out of way.
(17) Remove clutch release access cover.
(18)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 22).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 23). Disengage T-end
from release lever and secure cable out of way.
(19) Remove engine left mount bracket (Fig. 24).
(20) Remove starter motor (Fig. 25).
(21) Disconnect back-up lamp switch connector.
(22) Position screw jack and wood block to engine
oil pan.
(23) Remove transmission upper mount through-
bolt from left frame rail.
(24) Lower engine/transaxle assembly on screw
jack.(25) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 26).
(26) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(27) Remove transaxle from engine (Fig. 27).
(28) Inspect clutch, clutch release components, and
flywheel.
Fig. 22 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 23 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 24 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
RGT850 MANUAL TRANSAXLE21a-15
T850 MANUAL TRANSAXLE (Continued)
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Fig. 25 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 26 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
Fig. 27 Transaxle Removal/Installation
1 - TRANSAXLE 2 - BOLT
21a - 16 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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DISASSEMBLY
(1) Remove clutch release lever and bearing (Fig.
28) (Fig. 29). Inspect release lever pivot balls and
replace if necessary (Fig. 30) (Fig. 31). Use slide
hammer C-3752 and remover/installer 6891 (Fig. 32)
if pivot ball replacement is necessary.
(2) Remove input shaft bearing retainer (Fig. 33).
NOTE: Place transaxle in neutral before shift cover
removal.
(3) Remove shift cover-to-case bolts and remove
shift cover assembly (Fig. 34).
Fig. 28 Release Bearing and Lever (LHD)
1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 29 Release Bearing and Lever (RHD)
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 30 Pivot Ball Position (LHD)
1 - PIVOT BALLS (2)
Fig. 31 Pivot Ball Position (RHD)
1 - PIVOT BALL (1)
RGT850 MANUAL TRANSAXLE21a-17
T850 MANUAL TRANSAXLE (Continued)
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(4) Using a suitable screwdriver, remove extension
housing axle oil seal (Fig. 35).Fig. 32 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 33 Input Bearing Retainer
1 - INPUT BEARING RETAINER
Fig. 34 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 35 Extension Housing Seal
1 - SCREWDRIVER
2 - EXTENSION HOUSING
3 - SEAL
21a - 18 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(5) Remove extension housing-to-case and differen-
tial cover bolts (Fig. 36).
(6) Place transaxle with bellhousing surface down.
(7) Remove backup lamp switch (Fig. 37).(8) Remove end plate (Fig. 38).
(9) Set up lifting bar (tool 8489) as shown in (Fig.
39).
(10) Lift up on bar (input shaft bearing side) and
remove input shaft bearing snap ring.
(11) Lift up on bar (intermediate shaft side) and
remove intermediate shaft bearing snap ring.
(12) Remove lifting bar 8489.
Fig. 36 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
Fig. 37 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 38 End Plate Bolts
1 - BOLT (11)
Fig. 39 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
RGT850 MANUAL TRANSAXLE21a-19
T850 MANUAL TRANSAXLE (Continued)
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(13) Remove end cover-to-case bolts (12) (Fig. 40).
(14) Remove end cover from transaxle (Fig. 41).
(15) Remove 3/4 shift rail bushing from end cover
using slide hammer C-3752 and remover 6786 (Fig.
42).
(16) Remove reverse idler bolt (Fig. 43). Remove
reverse idler gear, washers, and shaft upon geartrain
removal.
(17) Remove 1-2/5-R shift rail (Fig. 44).
(18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 45).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 45).
(21) Remove lifting bar from geartrain.NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(22) Reinstall and torque extension housing and
meaure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
(23) Remove differential cover bolts.
(24) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(25) Remove extension housing.
(26) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 46).
Fig. 40 End Cover Bolts
1 - BOLT (12)
Fig. 41 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 42 3/4 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 43 Reverse Idler Shaft Bolt
21a - 20 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(27) Remove differential chip collector magnet and
clean (Fig. 47).Magnet is adhered with RTV, and
may require force to remove.
(28) Remove intermediate shaft bearing race with
puller 8472 (Fig. 48).
(29) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 49).
(30) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 50).
Fig. 44 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 45 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 46 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 47 Differential Magnet
1 - MAGNET
RGT850 MANUAL TRANSAXLE21a-21
T850 MANUAL TRANSAXLE (Continued)
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