DODGE TOWN AND COUNTRY 2003 Service Manual

(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 20).(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove front harness retainer and secure
harness out of way.
(16) Using Tool 6638A, disconnect clutch hydrau-
lic circuit quick connect (located on slave cylinder
tube). Remove clutch slave cylinder by depressing
towards case and rotating counter-clockwise 60É,
while lifting anti-rotation tab out of case slot with
screwdriver (Fig. 21).
(17) Remove engine left mount bracket (Fig. 22).
(18) Remove starter motor (Fig. 23).
(19) Disconnect back-up lamp switch connector.
(20) Position screw jack and wood block to engine
oil pan.
(21) Remove transmission upper mount through-
bolt from left frame rail.
(22) Lower engine/transaxle assembly on screw
jack.
(23) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 24).
Fig. 19 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 20 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 21 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
21 - 34 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(24) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(25) Remove transaxle from engine (Fig. 25).
(26) Inspect clutch, clutch release components, and
flywheel.
DISASSEMBLY
(1) Remove clutch release lever and bearing (Fig.
26). Inspect release lever pivot balls and replace if
necessary (Fig. 27). Use slide hammer C-3752 and
remover/installer 6891 (Fig. 28) if pivot ball replace-
ment is necessary.
Fig. 22 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
Fig. 23 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 24 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
RST850 MANUAL TRANSAXLE21-35
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

Fig. 25 Transaxle Removal/Installation
1 - TRANSAXLE
2 - BOLT
Fig. 26 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 27 Pivot Ball Orientation
1 - PIVOT BALL (1)
21 - 36 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(2) Remove input shaft bearing retainer (Fig. 29).
NOTE: Place transaxle in neutral before shift cover
removal.(3) Remove shift cover-to-case bolts and remove
shift cover assembly (Fig. 30).
(4) Using a suitable screwdriver, remove extension
housing axle oil seal (Fig. 31).
Fig. 28 Pivot Ball Removal/Installation
1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 29 Input Bearing Retainer
1 - INPUT BEARING RETAINER
Fig. 30 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 31 Extension Housing Seal
1 - SCREWDRIVER
2 - EXTENSION HOUSING
3 - SEAL
RST850 MANUAL TRANSAXLE21-37
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(5) Remove extension housing-to-case and differen-
tial cover bolts (Fig. 32).
(6) Place transaxle with bellhousing surface down.
(7) Remove backup lamp switch (Fig. 33).(8) Remove end plate (Fig. 34).
(9) Set up lifting bar (tool 8489) as shown in (Fig.
35).
(10) Lift up on bar (input shaft bearing side) and
remove input shaft bearing snap ring.
(11) Lift up on bar (intermediate shaft side) and
remove intermediate shaft bearing snap ring.
Fig. 32 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
Fig. 33 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 34 End Plate Bolts
1 - BOLT (11)
Fig. 35 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
21 - 38 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(12) Remove lifting bar 8489.
(13) Remove end cover-to-case bolts (12) (Fig. 36).
(14) Remove end cover from transaxle (Fig. 37).(15) Remove 3/4 shift rail bushing from end cover
using slide hammer C-3752 and remover 6786 (Fig.
38).
(16) Remove reverse idler bolt (Fig. 39). Remove
reverse idler gear, washers, and shaft upon geartrain
removal.
Fig. 36 End Cover Bolts
1 - BOLT (12)
Fig. 37 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 38 3/4 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 39 Reverse Idler Shaft Bolt
RST850 MANUAL TRANSAXLE21-39
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(17) Remove 1-2/5-R shift rail (Fig. 40). (18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 41).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 41).
(21) Remove lifting bar from geartrain.
NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(22) Reinstall and torque extension housing and
measure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
(23) Remove differential cover bolts.
(24) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(25) Remove extension housing.
(26) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 42).
Fig. 40 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 41 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 42 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
21 - 40 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(27) Remove differential chip collector magnet and
clean (Fig. 43).Magnet is adhered with RTV, and
may require force to remove.
(28) Remove intermediate shaft bearing race with
puller 8472 (Fig. 44).(29) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 45).
(30) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 46).
Fig. 43 Differential Magnet
1 - MAGNET
Fig. 44 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 45 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
RST850 MANUAL TRANSAXLE21-41
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

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. 47).
(2) Install shift shaft bushing to case using
installer 8475 (Fig. 48).
Fig. 46 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
Fig. 47 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 48 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
21 - 42 T850 MANUAL TRANSAXLERS
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. 49). 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. 50).(5) Install shift forks and 3/4 rail assembly to
geartrain as shown in (Fig. 51).
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)
Fig. 49 Install Intermediate Shaft Bearing Race
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - INSTALLER 8471
4 - INTERMEDIATE SHAFT BEARING RACEFig. 50 Install Geartrain to Fixture 8487
1 - INTERMEDIATE SHAFT
2 - INPUT SHAFT
2 - FIXTURE 8487
RST850 MANUAL TRANSAXLE21-43
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com