DODGE TOWN AND COUNTRY 2001 Service Manual

(8) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(10)RHD Models:Install clutch slave cylinder
into position, noting orientation of different sized
lugs (Fig. 85). While depressing inward, rotate slave
cylinder clockwise 60tÉ into position until nylon
locating tab rests within transaxle case cutout, and
hydraulic tube is vertical. Connect ªquick-connectº
connection until an audible ªclickº is heard. Verify
connection by pulling outward on connection.LHD
Models:Insert T-end of clutch release cable into
clutch release lever provision. Route cable through
transaxle case cutout, and seat cable housing with
grommet to transaxle case (Fig. 86).
(11) Install clutch access hole cover.
(12) Install cradle plate.
(13) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(14) Lower vehicle.
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 86 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 32 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(15) Install right mount bracket to transaxle (Fig.
87).
(16) Connect gearshift cables to shift levers/cover
assembly (Fig. 88). Install cables into position at
mount bracket and secure with retaining clips.
(17) Connect battery cables.
(18) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
INSTALLATION - 2.5L TD
(1) Assemble transaxle to engine, while aligning
transaxle input shaft to clutch disc splines.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.) (Fig. 89).
(3) Install transaxle upper mount (Fig. 90). Install
and torque four (4) mount-to-transaxle bolts to 54
N´m (40 ft. lbs.).
(4) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(5) Remove screw jack.
(6) Connect back-up lamp switch connector.
(7) Install starter motor into position (Fig. 91).
Install and torque bolts to 54 N´m (40 ft. lbs.).Fig. 87 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 88 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RGT850 MANUAL TRANSAXLE21a-33
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

Fig. 89 Transaxle Removal/Installation
1 - TRANSAXLE 2 - BOLT
Fig. 90 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
Fig. 91 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
21a - 34 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9)RHD Models:Install clutch slave cylinder into
position, noting orientation of different sized lugs
(Fig. 92). While depressing inward, rotate slave cyl-
inder clockwise 60É into position until nylon locating
tab rests within transaxle case cutout, and hydraulic
tube is vertical. Connect ªquick-connectº connection
until an audible ªclickº is heard. Verify connection by
pulling outward on connection.LHD Models:Insert
T-end of clutch release cable into clutch release lever
provision. Route cable through transaxle case cutout,
and seat cable housing with grommet to transaxle
case (Fig. 93).
(10) Install clutch access hole cover.
(11) Install cradle plate.
(12) Install underbody splash panel.
(13) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(14) Lower vehicle.
(15) Install right mount bracket to transaxle (Fig.
94).
Fig. 92 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 93 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 94 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RGT850 MANUAL TRANSAXLE21a-35
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(16) Connect gearshift cables to shift levers/cover
assembly (Fig. 95). Install cables into position at
mount bracket and secure with retaining clips.
(17) Install coolant recovery bottle bracket (Fig.
96).(18) Install coolant recovery bottle to bracket.
(19) Connect battery temperature sensor and
install battery tray (Fig. 97).
(20) Install battery, hold-down clamp and nut (Fig.
98).
Fig. 95 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 96 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 97 Battery Tray
1 - BATTERY TRAY
Fig. 98 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
21a - 36 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(21) Install battery thermal shield and clutch cable
eyelet (LHD only) (Fig. 99). Verify proper clutch cable
routing (LHD models). Cable should be routed over
guide, through eyelet, and around coolant bottle and
wiring harness.
(22) Connect battery cables.
(23) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
SPECIFICATIONS
SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.46
2nd 2.07 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.53
Overall Top Gear 3.12 2.66
Fig. 99 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RGT850 MANUAL TRANSAXLE21a-37
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear 0.66-1.84 mm (0.026-0.072 in.)
2nd Gear 0.66-1.84 mm (0.026-0.072 in.)
5th Gear 0.86-1.54 mm (0.034-0.061 in.)
Reverse 0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear 0.091-0.828 mm (0.004-0.033 in.)
2nd Gear 0.051-0.787 mm (0.002-0.031 in.)
5th Gear 0.102-0.762 mm (0.004-0.030 in.)
Reverse 0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION METRIC STANDARD
Differential Turning Torque 2.3-3.4 N´m 20-30 in. lbs.
Side Gear End Play (each side) 0.025-0.152 mm 0.001-0.006 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential Cover-to-Case 54 40 Ð
Bolt, End Cover-to-Case 28 Ð 250
Bolt, End Cover Plate-to-Cover 28 Ð 250
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Reverse Idler Shaft-to-Case 54 40 Ð
Bolt, Ring Gear-to-Differential Case 95 70 Ð
Bolt, Shift Cover-to-Case 28 Ð 250
Nut, 5th Gear-to-Input Shaft 200 148 Ð
Plug, Drain 23 17 Ð
Screw, Input Bearing Retainer 12 Ð 105
Switch, Back-Up Lamp 23 17 Ð
Vent 7 Ð 60
21a - 38 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

SPECIAL TOOLS
SPECIAL TOOLS - T850 TRANSAXLE
Bearing Splitter, P-334
Slide Hammer, C-3752
Universal Handle, C-4171
Torque Tool, C-4995
Puller Set, 5048
Disconnect Tool, 6638A
Remover/Installer, 6891
RGT850 MANUAL TRANSAXLE21a-39
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

Alignment Pins, 8470
Installer, 8471
Race Remover, 8472
Bearing Installer, 8473
Remover/Installer, 8474
Installer, 8475
Installer, 8476
Wrench, 8478
21a - 40 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

Stake Tool, 8479
Installer, 8481
Bearing Installer, 8482
Fixture, 8483
Remover, 8486
Fixture, 8487
Lifting Bar, 8489
Thrust Buttons, 8491
RGT850 MANUAL TRANSAXLE21a-41
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com