Chrysler RG Voyager. Manual — part 507

(19) Install lifting bar 8489 to geartrain.
(20) Lift up on bar (input shaft side) and install

input shaft bearing snap ring (Fig. 73).

(21) Lift up on bar (intermediate shaft side) and

install intermediate shaft bearing snap ring.

(22) Remove lifting bar 8489.
(23) Install a bead of Mopar

t Gear Lube RTV to

end plate and immediately install to case. Install and
torque bolts to 28 N·m (250 in. lbs.) (Fig. 74).

(24) Install back up lamp switch. Use Tool 8827

and torque to 23 N·m (17 ft. lbs.) (Fig. 75).

(25) Roll transaxle assembly on side.
(26) Install differential chip collector magnet (Fig.

76). Retain to case with a dab of Mopar

t Gear Lube

RTV.

Fig. 73 Input Bearing Snap Ring

1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING

Fig. 74 End Cover Bolts

1 - BOLT (11)

Fig. 75 Back-Up Lamp Switch — Typical

1 - BACK-UP LAMP SWITCH

Fig. 76 Differential Magnet

1 - MAGNET

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T850 MANUAL TRANSAXLE

RG

T850 MANUAL TRANSAXLE (Continued)

(27) Install differential assembly with bearing

races and select shim (Fig. 77). Shim selection was
determined before transaxle assembly (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS).

(28) Install a 1 mm (0.04 in.) bead of Mopar

t Gas-

ket Maker to differential cover and install to case.
Torque differential cover-to-case bolts to 54 N·m (40
ft. lbs.).

(29) Install a 1 mm (0.04 in.) bead of Mopar

t Gas-

ket Maker to extension housing. Install extension
housing to differential cover and case and torque
bolts to 28 N·m (250 in. lbs.) (Fig. 78).

(30) Install both axle new output shaft seals using

driver handle C-4171 and installer 8476 (Fig. 79)
(Fig. 80).

Fig. 77 Differential Shim/Slinger Orientation

1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)

Fig. 78 Extension Housing-to-Case Bolts

1 - EXTENSION HOUSING

Fig. 79 Axle Seal Installation (Extension Housing

Side)

1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171

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T850 MANUAL TRANSAXLE

21a - 51

T850 MANUAL TRANSAXLE (Continued)

(31) Install impact blocker (If Equipped) (Fig. 81).

(32) Apply a 1 mm (0.04 in.) bead of Mopar

t Gas-

ket Maker to shift cover assembly. Place shift cover
and transaxle geartrain into neutral and install shift
cover (Fig. 82) and torque bolts to 28 N·m (250 in.
lbs.).

(33) Reinstall shift selector lever if previously

removed.

(34) Install input shaft bearing retainer (Fig. 83).

Torque bolts to 12 N·m (105 in. lbs.).

Fig. 80 Axle Seal Installation—Typical

1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171

Fig. 81 Impact Blocker (SRT-4 Models)

1 - IMPACT BLOCKER (SRT-4 Models)
2 - NUT (2)
3 - DIFFERENTIAL COVER

Fig. 82 Shift Cover Removal/Installation

1 - SHIFT COVER ASSEMBLY

Fig. 83 Input Bearing Retainer

1 - INPUT BEARING RETAINER

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T850 MANUAL TRANSAXLE

RG

T850 MANUAL TRANSAXLE (Continued)

(35) If previously removed, install clutch release

lever pivot ball(s) using slide hammer C-3752 and
remover/installer 6891 (Fig. 84) (Fig. 85).

(36) Install clutch release bearing to lever. Apply

grease to interface (contact) points. Make sure
release bearing retainers engage lever pocket as
shown in (Fig. 86).

(37) Apply grease to pivot ball(s), and on release

lever at slave cylinder contact point.

(38) Install clutch release bearing/lever assembly

into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball (Fig. 87). A “pop” sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.

Fig. 84 Pivot Ball Removal/Installation

1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL

Fig. 85 Pivot Ball Position

1 - PIVOT BALL (1)

Fig. 86 Release Bearing-to-Lever

1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING

Fig. 87 Release Bearing and Lever

1 - RELEASE LEVER
2 - RELEASE BEARING

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T850 MANUAL TRANSAXLE

21a - 53

T850 MANUAL TRANSAXLE (Continued)