Chrysler RG Voyager. Manual — part 521
DISASSEMBLY
CAUTION: Do not re-use snap rings when servicing
the intermediate shaft assembly. Discard upon dis-
assembly and install new ones provided with avail-
able snap ring service kit.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear.
(2) Install 8486-4 button to intermediate shaft.
Using arbor press ram, press reverse gear and inter-
mediate roller bearing off of shaft, while holding
remaining assembly with hand (Fig. 242).
(3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 243).
(5) Remove 5/R synchro snap ring (Fig. 244).
Fig. 242 Bearing and Reverse Gear Removal
1 - ARBOR PRESS RAM
2 - ADAPTER
3 - SEALED ROLLER BEARING
4 - REVERSE GEAR
5 - BEARING SPLITTER P-334
Fig. 243 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 244 5/R Synchro Snap Ring
1 - SNAP RING
21a - 106
T850 MANUAL TRANSAXLE
RG
INTERMEDIATE SHAFT (Continued)
(6) Remove 5/R synchro (Fig. 245).
(7) Remove 5th gear blocker ring (Fig. 246).
(8) Remove 5th gear and needle bearing (Fig. 247)
(Fig. 248).
Fig. 245 5/R Synchronizer
1 - 5/R SYNCHRO ASSEMBLY
Fig. 246 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 247 5th Gear Removal/Installation
1 - 5TH GEAR
2 - NEEDLE BEARING
Fig. 248 5th Gear Needle Bearing Removal/
Installation
1 - 5TH GEAR NEEDLE BEARING
RG
T850 MANUAL TRANSAXLE
21a - 107
INTERMEDIATE SHAFT (Continued)
(9) Remove 3/4 cluster gear snap ring (Fig. 249).
(10) Install shaft assembly into fixture 8483, with
split collar 8483-3 oriented chamfer side up (Fig.
250). Place 8483-2 into position with chamfer side up
(Fig. 251).
(11) Using an arbor press, press intermediate shaft
out of 3/4 cluster gear (Fig. 252).
Fig. 249 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 250 Fixture 8483
1 - FIXTURE 8483
2 - COLLAR 8483-3
Fig. 251 Loading Intermediate Shaft
1 - FIXTURE 8483
2 - 3/4 CLUSTER GEAR
3 - COLLAR 8483-2
Fig. 252 Press Intermediate Shaft Out of 3/4 Cluster
Gear
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - 3/4 CLUSTER GEAR
4 - FIXTURE 8483
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T850 MANUAL TRANSAXLE
RG
INTERMEDIATE SHAFT (Continued)
(12) Remove intermediate shaft from fixture and
remove 3/4 cluster gear from shaft (Fig. 253).
(13) Remove 2nd gear and needle bearing (Fig.
254) (Fig. 255).
(14) Remove 2nd gear reactor ring (Fig. 256).
Fig. 253 3/4 Cluster Gear
1 - 3/4 CLUSTER GEAR
2 - INTERMEDIATE SHAFT
Fig. 254 2nd Gear Removal/Installation
1 - 2ND GEAR
2 - NEEDLE BEARING
Fig. 255 2nd Gear Needle Bearing Removal/
Installation
1 - NEEDLE BEARING
Fig. 256 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
RG
T850 MANUAL TRANSAXLE
21a - 109
INTERMEDIATE SHAFT (Continued)
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