DODGE TOWN AND COUNTRY 2001 Service Manual

ASSEMBLY
NOTE: When assembling this transaxle, always use
NEW snap rings.
NOTE: Before assembling transaxle, differential
turning torque must be measured and adjusted.
(Refer to 21 - TRANSMISSION/TRANSAXLE/MANU-
AL/DIFFERENTIAL - ADJUSTMENTS). Differential
turning torque must be measured with geartrain out
of case.
(1) Install input shaft bearing using an arbor press
and remover/installer 8474 (Fig. 51).
(2) Install shift shaft bushing to case using
installer 8475 (Fig. 52).
Fig. 48 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 49 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 50 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
21a - 22 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(3) Install intermediate shaft bearing race to case
with an arbor press, driver handle C-4171, and
installer 8471 (Fig. 53). Press until installer 8471
bottoms on transaxle case.
NOTE: If input shaft assembly was not disassem-
bled, it is necessary to remove input shaft sealed
ball bearing before assembling transaxle. (Refer to
21 - TRANSMISSION/TRANSAXLE/MANUAL/INPUT
SHAFT - DISASSEMBLY)
(4) Install assembled input and intermediate
shafts to fixture 8487 (Fig. 54).
(5) Install shift forks and 3/4 rail assembly to
geartrain as shown in (Fig. 55).
NOTE: Before installing geartrain, make sure that
input shaft sealed roller bearing is not installed,
otherwise reverse idler assembly installation will be
difficult. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/INPUT SHAFT - DISASSEMBLY)
(6) Install lifting bar 8489 to geartrain. Install
geartrain to case.When installing geartrain to
case, use care not to damage bearing surfaces.
Fig. 51 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 52 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
Fig. 53 Install Intermediate Shaft Bearing Race
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - INSTALLER 8471
4 - INTERMEDIATE SHAFT BEARING RACE
RGT850 MANUAL TRANSAXLE21a-23
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(7) Remove lifting bar 8489 from geartrain.
(8) Install shift 1/2-5/R rail as shown in (Fig. 56).
(9) Install reverse idler shaft into position (Fig.
57). Install and torque shaft-to-case bolt to 54 N´m
(40 ft. lbs.).(10) Install reverse idler gear bearing (Fig. 58).
(11) Install reverse idler gear with hub down as
shown in (Fig. 59).
(12) Install flat washer (Fig. 60).
(13) Install wave washer (Fig. 61).
(14) Install input shaft sealed roller bearing using
installer 8482 (Fig. 62).
(15) Installnewinput shaft bearing snap ring
(Fig. 63).
Fig. 54 Install Geartrain to Fixture 8487
1 - INTERMEDIATE SHAFT
2 - INPUT SHAFT
3 - FIXTURE 8487
Fig. 55 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
21a - 24 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

Fig. 56 Shift Rail Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 57 Install Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
2 - BOLT
Fig. 58 Install Reverse Idler Gear Bearing
1 - NEEDLE BEARING
2 - REVERSE IDLER SHAFT
Fig. 59 Install Reverse Idler Gear
1 - REVERSE IDLER GEAR
RGT850 MANUAL TRANSAXLE21a-25
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

Fig. 60 Install Flat Washer
1 - FLAT WASHER
Fig. 61 Install Wave Washer
1 - WAVE WASHER
Fig. 62 Install Input Shaft Sealed Roller Bearing
1 - INSTALLER 8482
2 - SEALED ROLLER BEARING
Fig. 63 Input Shaft Bearing Snap Ring
1 - SNAP RING
21a - 26 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(16) Install shift rail bushing to end cover using
installer 8475 (Fig. 64).
(17) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to transaxle end cover and install to
transaxle case (Fig. 65).While installing end
cover, be sure to guide oil trough into pocket
(Fig. 66).Torque end cover-to-case bolts to 28 N´m
(250 in. lbs.) (Fig. 67).
(18) Install lifting bar 8489 to geartrain.
(19) Lift up on bar (input shaft side) and install
input shaft bearing snap ring (Fig. 68).
(20) Lift up on bar (intermediate shaft side) and
install intermediate shaft bearing snap ring.
(21) Remove lifting bar 8489.
(22) Install a bead of MopartGear Lube RTV to
end plate and immediately install to case. Install and
torque bolts to 28 N´m (250 in. lbs.) (Fig. 69).
(23) Install back up lamp switch and torque to 23
N´m (17 ft. lbs.) (Fig. 70).
Fig. 64 Shift Rail Bushing Installation
1 - INSTALLER 8475
Fig. 65 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 66 Oil Trough Pocket
1 - OIL TROUGH
2 - POCKET
Fig. 67 End Cover Bolts
1 - BOLT (12)
RGT850 MANUAL TRANSAXLE21a-27
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(24) Roll transaxle assembly on side.
(25) Install differential chip collector magnet (Fig.
71). Retain to case with a dab of MopartGear Lube
RTV.(26) Install differential assembly with bearing
races and select shim (Fig. 72). Shim selection was
determined before transaxle assembly (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS).
Fig. 68 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
Fig. 69 End Plate Bolts
1 - BOLT (11)
Fig. 70 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 71 Differential Magnet
1 - MAGNET
21a - 28 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(27) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to differential cover and install to case.
Torque differential cover-to-case bolts to 54 N´m (40
ft. lbs.).
(28) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to extension housing. Install extension
housing to differential cover and case and torque
bolts to 28 N´m (250 in. lbs.) (Fig. 73).(29) Install both axle output shaft seals using
driver handle C-4171 and installer 8473 (Fig. 74)
(Fig. 75).
(30) Applya1mm(0.04 in.) bead of MopartGasket
Maker to shift cover assembly. Place shift cover and
transaxle geartrain into neutral and install shift cover
(Fig. 76) and torque bolts to 28 N´m (250 in. lbs.).
Fig. 72 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 73 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
Fig. 74 Axle Seal Installation
(Extension Housing Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
Fig. 75 Axle Seal Installation
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
RGT850 MANUAL TRANSAXLE21a-29
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(31) Install input shaft bearing retainer (Fig. 77).
Torque bolts to 12 N´m (105 in. lbs.).
(32) If previously removed, install clutch release
lever pivot ball(s) using slide hammer C-3752 and
remover/installer 6891 (Fig. 78) (Fig. 79) (Fig. 80).
(33) Install clutch release bearing to lever. Apply
grease to interface (contact) points. Make sure
release bearing retainers engage lever pocket as
shown in (Fig. 81).
(34) Apply grease to pivot ball(s), and on RHD
release lever at slave cylinder contact point.
(35) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seatrelease lever to pivot ball(s) (Fig. 82) (Fig. 83). A
ªpopº sound should be heard.Make sure LHD lever
is secured to BOTH pivot balls.Verify proper
engagement by lightly pulling outward on lever at
pivot ball location, and then actuating lever and
bearing to ensure proper operation.
Fig. 76 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 77 Input Bearing Retainer
1 - INPUT BEARING RETAINER
Fig. 78 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 79 Pivot Ball Position (LHD)
1 - PIVOT BALLS (2)
21a - 30 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
Fig. 80 Pivot Ball Position (RHD)
1 - PIVOT BALL (1)
Fig. 81 Release Bearing-to-Lever (LHD ShownÐRHD
Typical)
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 82 Release Bearing and Lever (LHD)
1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 83 Release Bearing and Lever (RHD)
1 - RELEASE LEVER
2 - RELEASE BEARING
RGT850 MANUAL TRANSAXLE21a-31
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com