Chrysler RG Voyager. Manual — part 523
(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 270).
(2) Install intermediate shaft roller bearing snap
ring (Fig. 271).
(3) Install 1st gear thrust bearing (Fig. 272). Blue
markings on bearing should face down towards out-
put gear.
(4) Install 1st gear needle bearing to intermediate
shaft (Fig. 273).
Fig. 270 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
Fig. 271 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 272 1st Gear Thrust Bearing Removal/
Installation
1 - THRUST BEARING
Fig. 273 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
21a - 114
T850 MANUAL TRANSAXLE
RG
INTERMEDIATE SHAFT (Continued)
(5) Install 1st gear to intermediate shaft (Fig.
274).
(6) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 275).
(7) Install intermediate shaft to synchro assembly
on fixture (Fig. 276). When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal. Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture.
Fig. 274 1st Gear Installation
1 - 1ST GEAR
Fig. 275 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
Fig. 276 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
RG
T850 MANUAL TRANSAXLE
21a - 115
INTERMEDIATE SHAFT (Continued)
(8) Install NEW 1/2 synchro snap ring (Fig. 277).
(9) Install 2nd gear blocker ring (Fig. 278).
(10) Install 2nd gear friction cone (Fig. 279).
(11) Install 2nd gear reactor ring (Fig. 280).
Fig. 277 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 278 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 279 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 280 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
21a - 116
T850 MANUAL TRANSAXLE
RG
INTERMEDIATE SHAFT (Continued)
(12) Install 2nd gear and needle bearing to inter-
mediate shaft (Fig. 281) (Fig. 282).
(13) Press 3/4 cluster gear onto intermediate shaft
using cup 8481 (Fig. 283).
(14) Install NEW 3/4 cluster gear snap ring (Fig.
284).
Fig. 281 2nd Gear Removal/Installation
1 - 2ND GEAR
2 - NEEDLE BEARING
Fig. 282 2nd Gear Needle Bearing Removal/
Installation
1 - NEEDLE BEARING
Fig. 283 Install 3/4 Cluster Gear using Tool 8481
1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR
Fig. 284 3/4 Cluster Gear Snap Ring
1 - SNAP RING
RG
T850 MANUAL TRANSAXLE
21a - 117
INTERMEDIATE SHAFT (Continued)
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