torque DODGE TOWN AND COUNTRY 2001 Service Manual

(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)
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(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)
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(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)
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(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)
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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)
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(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)
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(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)
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(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)
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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)
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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)
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