DODGE TOWN AND COUNTRY 2001 Service Manual

ADJUSTMENT - DIFFERENTIAL SIDE GEAR
END PLAY
Measure side gear end play: Insert feeler gauges
180É apart between differential side gear and thrust
washer as shown in (Fig. 132). Measurement taken
here applies to both sides. Side gear end play should
be between 0.025-0.152 mm (0.001-0.006 in.). If clear-
ance is greater than 0.152 mm (0.006 in.), install a
thicker thrust washer (both sides). If clearance is less
than 0.025 mm (0.001), install a thinner thrust
washer (both sides). Refer to (Fig. 133) for available
side gear shim thicknesses.
If end play measurement indicates a thrust washer
change is necessary, the differential must be disas-
sembled. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/DIFFERENTIAL - DISASSEMBLY)
FLUID
STANDARD PROCEDURE - FLUID LEVEL
CHECK
NOTE: For proper fluid level check intervals, (Refer
to LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
(1) Raise vehicle on hoist.
(2) Remove transaxle fill plug (Fig. 134).(3) Inspect fluid level. Fluid should be within 1/8º
below fill hole. Add MopartATF+4 (Automatic Trans-
mission FluidÐType 9602) as neccessary.
(4) Install fill plug, ensuring it is properly seated.
(5) Lower vehicle.
Fig. 132 Side Gear End Play Measurement
1 - FEELER GAUGE
Fig. 133 Available Side Gear Thrust Washers
1 - (PLAIN) 0.79-0.84 mm (0.031-0.033 in.)
2 - ( TRIANGLE) 0.91-0.97 mm (0.036-0.038 in.)
3 - (SQUARE) 1.04-1.10 mm (0.041-0.043 in.)
4 - (DIAMOND) 1.17-1.22 mm (0.046-0.048 in.)
Fig. 134 Transaxle Fill Plug
1 - TRANSAXLE FILL PLUG
2 - END COVER
21a - 52 T850 MANUAL TRANSAXLERG
DIFFERENTIAL (Continued)
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STANDARD PROCEDURE - FLUID DRAIN AND
FILL
NOTE: For proper fluid change intervals, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 135) and
drain fluid into suitable container.
(3) Install drain plug and torque to 14 N´m (120
in. lbs.).
FLUID FILL
(1) Remove transaxle fill plug (Fig. 136).
(2) Add 2.4-2.7L (2.5-2.9 qts.) of MopartATF+4
(Automatic Transmission FluidÐType 9602) until
fluid is within 1/8º below fill hole.
(3) Install fill plug, ensuring it is properly seated.
(4) Lower vehicle.
GEARSHIFT BOOT
REMOVAL
(1) Remove gearshift knob by pushing down and
rotating ò-turn clockwise (Fig. 137).(2) Remove gearshift boot from center console by
disengaging three (3) retaining clips (Fig. 138).
INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 138).
(2) Install gearshift knob (Fig. 137). Orient shift
pattern ò-turn clockwise, press down, and rotate
ò-turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
Fig. 135 Transaxle Drain Plug
1 - TRANSAXLE DRAIN PLUG
2 - DIFFERENTIAL COVER
Fig. 136 Transaxle Fill Plug
1 - TRANSAXLE FILL PLUG
2 - END COVER
Fig. 137 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-53
FLUID (Continued)
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GEARSHIFT CABLE -
CROSSOVER
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clock-wise (Fig. 139).(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 140).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
141).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
142).
Fig. 138 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 139 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 140 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 141 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
21a - 54 T850 MANUAL TRANSAXLERG
GEARSHIFT BOOT (Continued)
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(7) Remove center console support bracket (Fig.
143).
(8) Remove crossover cable retainer clip (Fig. 144).
(9) Remove crossover cable from gearshift mecha-
nism (Fig. 145).(10)2.4L Gas equipped models goto Step 15.
2.5L TD models:Remove battery thermal shield
(Fig. 146).
(11) Remove battery hold down nut, clamp, and
battery (Fig. 147).
(12) Remove battery tray (Fig. 148). Disconnect
battery temperature sensor.
(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 149).
(15) Disconnect crossover cable from transaxle
crossover lever (Fig. 150).
Fig. 142 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 143 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 144 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
Fig. 145 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
RGT850 MANUAL TRANSAXLE21a-55
GEARSHIFT CABLE - CROSSOVER (Continued)
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(16) Remove crossover cable retainer clip and dis-
engage cable from mount bracket (Fig. 150).
(17) Raise vehicle on hoist.
(18) Remove crossover cable from engine compart-
ment, then remove cable from passenger compart-
ment through opening in floor pan.
INSTALLATION
(1) From underneath vehicle, install gearshift
crossover cable into passenger compartment throughfloor pan hole. Install remainder of cable into posi-
tion in engine compartment.
(2) Lower vehicle.
(3) Install crossover cable to mount bracket and
secure with retainer clip (Fig. 151).
(4) Install cable to transaxle crossover lever (Fig.
151).
Fig. 146 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 147 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 148 Battery Tray
1 - BATTERY TRAY
Fig. 149 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
21a - 56 T850 MANUAL TRANSAXLERG
GEARSHIFT CABLE - CROSSOVER (Continued)
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(5)2.4L Gas models goto Step 10. 2.5L TD
Models:Install coolant recovery bottle bracket (Fig.
152).
(6) Install coolant recovery bottle to bracket.(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 153).
Fig. 150 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 151 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 152 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 153 Battery Tray
1 - BATTERY TRAY
RGT850 MANUAL TRANSAXLE21a-57
GEARSHIFT CABLE - CROSSOVER (Continued)
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(8) Install battery, hold-down clamp, and nut (Fig.
154).
(9) Install battery thermal shield (Fig. 155).(10) Install crossover cable to gearshift mechanism
(Fig. 156). Install retainer clip (Fig. 157).
(11) Adjust crossover cable (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL/GEAR SHIFT
CABLE - ADJUSTMENTS).
Fig. 154 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 155 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 156 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
Fig. 157 Crossover Cable Retainer Clip
1 - RETAINER CLIP
2 - CROSSOVER CABLE
21a - 58 T850 MANUAL TRANSAXLERG
GEARSHIFT CABLE - CROSSOVER (Continued)
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(12) Install center console support bracket (Fig.
158). Torque support bracket-to-gearshift mechanism
screws to 12 N´m (108 in. lbs.).
(13) Install center console assembly (Fig. 159).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).(14) Install cupholder plugs (Fig. 160).
(15) Install gearshift boot to console (Fig. 161).
Secure with three (3) retainer clips.
(16) Install gearshift knob to gearshift lever (Fig.
162). Orient shift pattern ò-turn clockwise, push
down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(17) Connect battery negative cable.
Fig. 158 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 159 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 160 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 161 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
RGT850 MANUAL TRANSAXLE21a-59
GEARSHIFT CABLE - CROSSOVER (Continued)
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ADJUSTMENT
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clock-wise (Fig. 163).(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 164).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
165).
Fig. 162 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 163 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 164 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 165 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
21a - 60 T850 MANUAL TRANSAXLERG
GEARSHIFT CABLE - CROSSOVER (Continued)
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(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
166).
(7) Loosen crossover cable adjustment screw (Fig.
167).
(8) Rock gearshift lever back and forth between
1±2 and 5±R planes. Release lever, allowing shifterspring to return lever to the neutral position in the
3±4 plane. Place gearshift lever in the 3rd gear posi-
tion.
(9) Torque crossover lever adjustment screw to 8
N´m (70 in. lbs.).No load should be applied to
the shifter lever in any direction (hands off)
while tightening screw.
(10) Verify gearshift lever travel through all gear
ranges with engine off (not running).
(11) Install center console assembly (Fig. 166).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(12) Install cupholder plugs (Fig. 165).
(13) Install gearshift boot to console (Fig. 164).
Secure boot to console with three (3) retainer clips.
(14) Install gearshift knob to gearshift lever (Fig.
163). Orient shift pattern on knob ò-turn clockwise,
push down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(15) Connect battery negative cable.
GEARSHIFT CABLE -
SELECTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clock-wise (Fig. 168).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 169).
Fig. 166 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 167 Crossover Cable Adjustment Screw
1 - CROSSOVER CABLE
2 - ADJUSTMENT SCREW
Fig. 168 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-61
GEARSHIFT CABLE - CROSSOVER (Continued)
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