DODGE TOWN AND COUNTRY 2003 Service Manual

INSTALLATION
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal
(Fig. 34). When installing seal the spring side of the
seal must face toward the special tool.
Fig. 31 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 32 Bearing Race Removal
1 - END COVER
2 - SPECIAL TOOL
No. 6514
Fig. 33 Seal Removal
1 - END COVER
2 - SPECIAL TOOL
7794±A
3 - SLIDE HAMMER
4 - SOFT JAW VICE
Fig. 34 Seal Installation
1 - SPECIAL TOOL No. MD998803
2 - HAMMER
3 - END COVER
21 - 14 POWER TRANSFER UNITRS
INPUT SHAFT COVER SEAL (Continued)
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(3) Reinstall the original bearing race and shim
using special tool No. 6522 (Fig. 35) and (Fig. 36).
CAUTION: The original shim must be installed behind
the bearing cup to maintain proper bearing preload.
(4)Apply MopartGasket Maker, Loctite Gasket
Eliminator No. 518 or equivalent to sealing surfaces of
end cover.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 37). Retighten first bolt after
all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
INPUT SHAFT END SEAL
REMOVAL
The input shaft end seal is located on the end of
the input shaft.
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 38).
Fig. 35 Bearing Shim and Race
1 - SHIM
2 - BEARING RACE
3 - END COVER
Fig. 36 Installing Bearing Race
1 - HAMMER
2 - END COVER
3 - SPECIAL TOOL No. 6522
4 - HANDLE 4171
Fig. 37 Bolt Tightening Sequence
Fig. 38 End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
RSPOWER TRANSFER UNIT21-15
INPUT SHAFT COVER SEAL (Continued)
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(3) Tap on end cover ears to separate end cover
from case (Fig. 39).
(4) Pry out seal with a pry bar (Fig. 40).INSTALLATION
The input shaft end seal is located on the end of
the input shaft.
(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into
input shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of MopartGasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 41). Retighten first bolt after
all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly.
(7) Check and fill fluids as required.
Fig. 39 Side Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 40 Seal Removal
1 - POWER TRANSFER UNIT
2 - PRYBAR
3 - SEAL
Fig. 41 Bolt Tightening Sequence
21 - 16 POWER TRANSFER UNITRS
INPUT SHAFT END SEAL (Continued)
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INPUT SHAFT SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 42).
(2) Gently tap on end cover ears to separate cover
from case (Fig. 43).
(3) Remove ring gear oil trough (Fig. 44).
(4) Remove input shaft and ring gear from case
(Fig. 45).
(5) Use Special Tool No. 7794-A (seal puller) to
remove seal (Fig. 46).
Fig. 42 P.T.U. End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 43 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 44 Oil Trough
1 - OIL TROUGH
2 - POWER TRANSFER UNIT
RSPOWER TRANSFER UNIT21-17
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INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 47). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.(3) Install input shaft.
(4) Install oil trough.
(5) Apply MopartGasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.)
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
Fig. 45 Input Shaft and Ring Gear Removal
1 - POWER TRANSFER UNIT
2 - RING GEAR
Fig. 46 Seal Removal
1 - POWER TRANSFER UNIT
2 - SPECIAL TOOL
7794±A
Fig. 47 Seal Installation
1 - HAMMER
2 - SPECIAL TOOL
C-4171
3 - SPECIAL TOOL
C-4657
4 - POWER TRANSFER UNIT
21 - 18 POWER TRANSFER UNITRS
INPUT SHAFT SEAL (Continued)
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OUTER HALF SHAFT SEAL
REMOVAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Lift vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove seal with a chisel and hammer (Fig.
48).
INSTALLATION
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Clean and inspect seal area.
(2) Install new seal with seal installer MD998334
(Fig. 49).
(3) Reinstall right front half shaft.
(4) Check and fill fluids as required.
REAR COVER O-RING
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear cover retaining bolts (Fig. 50).
Fig. 48 Seal Removal
1 - HAMMER
2 - CHISEL
3 - SEAL
4 - POWER TRANSFER UNIT
Fig. 49 Seal Installation
1 - BEARING
2 - SNAP RING PLIERS
3 - BEARING SNAP RING
Fig. 50 Rear Cover Bolts
1 - OUTPUT FLANGE SEAL
2 - REAR COVER
3 - OUTPUT SHAFT
RSPOWER TRANSFER UNIT21-19
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(3) Index rear cover to the case for later reassem-
bly (Fig. 51).
(4) Pull rear cover out of the P.T.U. case (Fig. 52).
(5) Remove rear cover O-Ring (Fig. 53).
INSTALLATION
(1) To install, reverse removal procedure.
Fig. 51 Mark Rear Cover
1 - REAR COVER
2 - OUTPUT SHAFT
3 - PAINT MARK
Fig. 52 Rear Cover Removal
1 - POWER TRANSFER UNIT ASSEMBLY
2 - REAR COVER
3 - O-RING
Fig. 53 O-Ring Removal
1 - REAR COVER
2 - PINION GEAR
3 - O-RING
21 - 20 POWER TRANSFER UNITRS
REAR COVER O-RING (Continued)
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T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION.........................21
OPERATION...........................24
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES....................30
REMOVAL.............................31
DISASSEMBLY.........................35
ASSEMBLY............................42
INSTALLATION.........................51
SPECIFICATIONS - T850 MANUAL
TRANSAXLE.........................56
SPECIAL TOOLS - T850 TRANSAXLE........58
AXLE SEALS
REMOVAL.............................61
INSTALLATION.........................61
BACK-UP LAMP SWITCH
REMOVAL.............................62
INSTALLATION.........................62
DIFFERENTIAL
DESCRIPTION.........................62
OPERATION...........................62
DISASSEMBLY.........................62
ASSEMBLY............................66
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE............................69
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY...........................70
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK.............................71
STANDARD PROCEDURE - FLUID DRAIN
AND FILL............................71
GEARSHIFT BOOT
REMOVAL.............................72
INSTALLATION.........................73GEARSHIFT CABLE - CROSSOVER
REMOVAL.............................73
INSTALLATION.........................76
ADJUSTMENTS
ADJUSTMENT........................79
GEARSHIFT CABLE - SELECTOR
REMOVAL.............................81
INSTALLATION.........................84
GEARSHIFT KNOB
REMOVAL.............................87
INSTALLATION.........................87
GEARSHIFT MECHANISM
REMOVAL.............................87
INSTALLATION.........................89
INPUT SHAFT
DESCRIPTION.........................93
DISASSEMBLY.........................93
ASSEMBLY............................96
INTERMEDIATE SHAFT
DESCRIPTION........................100
DISASSEMBLY........................100
ASSEMBLY...........................107
SHIFT COVER
DESCRIPTION........................113
SHIFT FORK AND SHAFT
DESCRIPTION........................113
SYNCHRONIZER
DESCRIPTION........................114
DISASSEMBLY........................114
CLEANING
CLEAN.............................114
INSPECTION
INSPECT...........................114
ASSEMBLY...........................114
VEHICLE SPEED SENSOR
REMOVAL............................115
INSTALLATION........................115
T850 MANUAL TRANSAXLE
DESCRIPTION
The NV T850 5-speed transaxle (Fig. 1) is a con-
stant-mesh manual transaxle that is synchronized in
all gear ranges, including reverse.The transaxle consists of three major sub-assem-
blies: the input shaft, intermediate shaft, and differ-
ential assembly. The transaxle shift system consists
of a mechanical shift cover, rails, forks, and cables.
The unique design of this shift system provides a
higher mechanical advantage, resulting in less fric-
tion and lower shift cable loads for smoother, more
positive operation.
RST850 MANUAL TRANSAXLE21-21
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Fig. 1 NV T850 Transaxle
1 - 3RD GEAR (SPEED) 9 - INTERMEDIATE SHAFT BEARING
(SEALED BALL)17 - 1/2 SYNCHRONIZER
2 - 3/4 SYNCHRONIZER 10 - REVERSE GEAR 18 - 1ST GEAR (SPEED)
3 - 3/4 SHIFT FORK 11 - 5/R SYNCHRONIZER 19 - DIFFERENTIAL ASSEMBLY
4 - 4TH GEAR (SPEED) 12 - 5/R SHIFT FORK 20 - EXTENSION HOUSING
5 - 5TH GEAR (INPUT) 13 - 5TH GEAR (SPEED) 21 - INTERMEDIATE SHAFT BEARING
(CAGED ROLLER)
6 - REVERSE IDLER GEAR 14 - 3/4 CLUSTER GEAR 22 - INTERMEDIATE SHAFT
7 - END COVER, REAR 15 - 2ND GEAR (SPEED) 23 - INPUT SHAFT
8 - INPUT SHAFT BEARING (SEALED
BALL)16 - 1/2 SHIFT FORK 24 - CASE
25 - INPUT SHAFT BEARING (ROLLER)
21 - 22 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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The NV T850 transaxle is available with the 2.4L
Gas and 2.5L Turbo Diesel engine options. Unique
gearing tailored to the performance characteristics of
each engine provides optimum driveability, gradabil-
ity, and acceleration. The gear ratios are as follows:
GEARRATIO (2.4L
Gas)RATIO (2.5L
TD)
1st 3.65 3.65
2nd 2.05 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive
Ratio3.77 3.77
Overall Top
Gear3.12 2.67
TRANSAXLE IDENTIFICATION
NOTE: Since transaxles use unique gear ratios for
each of the two engine applications, it is imperative
that the transaxle is properly identified, and the cor-
rect transaxle assembly number is used when
ordering service parts.The transaxle model, assembly part number, build
date, and final drive ratio (FDR) can be found on a
metal tag fastened to the transaxle case on the bell-
housing (Fig. 2). A barcode label is also glued to the
transaxle bellhousing, and it too includes the trans-
axle part number.
Fig. 2 T850 Transaxle Identification
1 - TRANSAXLE BELLHOUSING
2 - BARCODE LABEL
3 - I.D. TAG
RST850 MANUAL TRANSAXLE21-23
T850 MANUAL TRANSAXLE (Continued)
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