Chrysler RG Voyager. Manual — part 1023
(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.
(8) Install NEW 1/2 synchro snap ring (Fig. 277).
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
Fig. 277 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
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T850 MANUAL TRANSAXLE
21 - 113
INTERMEDIATE SHAFT (Continued)
(9) Install 2nd gear blocker ring (Fig. 278).
(10) Install 2nd gear friction cone (Fig. 279).
(11) Install 2nd gear reactor ring (Fig. 280).
(12) Install 2nd gear and needle bearing to inter-
mediate shaft (Fig. 281) (Fig. 282).
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
Fig. 281 2nd Gear Removal/Installation
1 - 2ND GEAR
2 - NEEDLE BEARING
21 - 114
T850 MANUAL TRANSAXLE
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INTERMEDIATE SHAFT (Continued)
(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).
(15) Install 5th gear and needle bearing to inter-
mediate shaft (Fig. 285) (Fig. 286).
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
Fig. 285 5th Gear Removal/Installation
1 - 5TH GEAR
2 - NEEDLE BEARING
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T850 MANUAL TRANSAXLE
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INTERMEDIATE SHAFT (Continued)
(16) Install 5th gear blocker ring to synchronizer
(Fig. 287).
(17) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 288). When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
(18) Install NEW 5/R synchro snap ring (Fig. 289).
(19) Install reverse gear blocker ring (Fig. 290).
Fig. 286 5th Gear Needle Bearing Removal/
Installation
1 - 5TH GEAR NEEDLE BEARING
Fig. 287 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 288 Install 5/R Synchro and 5th Blocker Ring to
5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
Fig. 289 5/R Synchro Snap Ring
1 - SNAP RING
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T850 MANUAL TRANSAXLE
RS
INTERMEDIATE SHAFT (Continued)
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