Chrysler RG Voyager. Manual — part 505
(22) Remove reverse idler shaft (Fig. 46).
(23) Remove 1-2/5-R shift rail (Fig. 47).
(24) Install lifting bar 8489.
(25) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 48).
(26) Remove remaining shift rail and forks from
geartrain (Fig. 48).
(27) Remove lifting bar from geartrain.
NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(28) Reinstall and torque extension housing and
measure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
Fig. 46 Reverse Shaft Removal/Installation
1 - SHAFT (w/SNAP RING)
2 - BOLT
Fig. 47 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 48 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
21a - 42
T850 MANUAL TRANSAXLE
RG
T850 MANUAL TRANSAXLE (Continued)
(29) Remove impact blocker (if equipped) (Fig. 49).
(30) Remove differential cover bolts.
(31) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(32) Remove extension housing.
(33) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 50).
(34) Remove differential chip collector magnet and
clean (Fig. 51). Magnet is adhered with RTV, and
may require force to remove.
Fig. 49 Impact Blocker (SRT-4 Models)
1 - IMPACT BLOCKER (SRT-4 Models)
2 - NUT (2)
3 - DIFFERENTIAL COVER
Fig. 50 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 51 Differential Magnet
1 - MAGNET
RG
T850 MANUAL TRANSAXLE
21a - 43
T850 MANUAL TRANSAXLE (Continued)
(35) Remove intermediate shaft bearing race with
puller 8472 (Fig. 52).
(36) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 53).
(37) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 54).
Fig. 52 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 53 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 54 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
21a - 44
T850 MANUAL TRANSAXLE
RG
T850 MANUAL TRANSAXLE (Continued)
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. 55).
(2) Install
shift
shaft
bushing
to
case
using
installer 8475 (Fig. 56).
(3) Install intermediate shaft bearing race to case
with an arbor press, driver handle C-4171, and
installer 8471 (Fig. 57). Press until installer 8471
bottoms on transaxle case.
Fig. 55 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 56 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
Fig. 57 Install Intermediate Shaft Bearing Race
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - INSTALLER 8471
4 - INTERMEDIATE SHAFT BEARING RACE
RG
T850 MANUAL TRANSAXLE
21a - 45
T850 MANUAL TRANSAXLE (Continued)
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