Chrysler RG Voyager. Manual — part 519
DISASSEMBLY
NOTE: When servicing the input shaft assembly, all
snap rings which are removed MUST be replaced
with new snap rings upon reassembly. The 5th gear
nut must be replaced also.
(1) Invert input shaft assembly and place in fix-
ture 8487.
(2) Remove input bearing snap ring (Fig. 216).
(3) Remove
input
bearing.
Place
input
shaft
assembly onto arbor press table, with the input bear-
ing supported by bearing splitter (Fig. 217). Using
adapter 8486-4, press bearing off of shaft, while
helper supports shaft to prevent dropping.
(4) Place input shaft assembly back into fixture
8487. Secure fixture to bench with fasteners, or
secure to bench vise.
NOTE: 5th gear nut is staked to the shaft. If neces-
sary, grind stake area to ease removal, but use care
not to contact gear.
(5) Remove 5th gear nut with wrench 8478 (Fig.
218). Discard nut and use a new one upon assembly.
(6) Remove 5th gear with arbor press and bearing
splitter.
Fig. 216 Input Bearing Snap Ring Removal
1 - SNAP RING
2 - INPUT BEARING
Fig. 217 Input Bearing Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - INPUT BEARING
4 - BEARING SPLITTER
Fig. 218 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
21a - 98
T850 MANUAL TRANSAXLE
RG
INPUT SHAFT (Continued)
(7) Remove 4th gear and needle bearing (Fig. 219)
(Fig. 220).
(8) Remove 4th gear blocker ring (Fig. 221).
(9) Remove 3/4 synchronizer snap ring (Fig. 222).
Discard and replace with new snap ring upon assem-
bly.
Fig. 219 4th Gear Removal/Installation
1 - 4TH GEAR
2 - NEEDLE BEARING
Fig. 220 4th Gear Needle Bearing Removal/
Installation
1 - 4TH GEAR NEEDLE BEARING
Fig. 221 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 222 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
RG
T850 MANUAL TRANSAXLE
21a - 99
INPUT SHAFT (Continued)
(10) Remove 3/4 synchronizer (Fig. 223).
(11) Remove 3rd gear blocker ring (Fig. 224).
(12) Remove 3rd gear and needle bearing (Fig.
225) (Fig. 226).
(13) Inspect third gear thrust washer for signs of
excessive wear. To replace, drive off of input shaft
with suitable drift and hammer.
Fig. 223 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 224 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 225 3rd Gear Removal/Installation
1 - 3RD GEAR
2 - NEEDLE BEARING
Fig. 226 3rd Gear Needle Bearing Removal/
Installation
1 - 3RD GEAR NEEDLE BEARING
2 - THRUST WASHER
21a - 100
T850 MANUAL TRANSAXLE
RG
INPUT SHAFT (Continued)
ASSEMBLY
NOTE: When servicing the input shaft assembly, all
snap rings MUST be replaced with new ones upon
assembly. 5th gear nut must also be replaced.
NOTE: When installing 3/4 synchronizer hub to
shaft, make sure to align oil slots on synchronizer
hub face with oil hole in the shaft splined hub jour-
nal.
NOTE: Refer to (Fig. 227) for input shaft assembly
reference.
(1) Install input shaft into fixture 8487.
(2) Install thrust washer if removed upon disas-
sembly.
(3) Install 3rd gear and needle bearing (Fig. 228)
(Fig. 229).
Fig. 227 Input Shaft Assembly
1 - INPUT SHAFT
7 - SNAP RING
2 - THRUST WASHER
8 - INPUT BEARING (SEALED)
3 - 3RD GEAR
9 - NEEDLE BEARING
4 - 4TH GEAR
10 - SNAP RING
5 - 5TH GEAR
11 - 3/4 SYNCHRONIZER
6 - 5TH GEAR NUT
12 - NEEDLE BEARING
Fig. 228 3rd Gear Needle Bearing Removal/Installation
1 - 3RD GEAR NEEDLE BEARING
2 - THRUST WASHER
RG
T850 MANUAL TRANSAXLE
21a - 101
INPUT SHAFT (Continued)
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