Chrysler RG Voyager. Manual — part 520

(4) Install 3rd gear blocker ring (Fig. 230).

(5) Install 3/4 synchronizer (Fig. 231). 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 journal.

(6) Install NEW 3/4 synchronizer snap ring (Fig.

232).

Fig. 229 3rd Gear Removal/Installation

1 - 3RD GEAR
2 - NEEDLE BEARING

Fig. 230 3rd Gear Blocker Ring

1 - 3RD GEAR BLOCKER RING

Fig. 231 3/4 Synchro Assembly

1 - 3/4 SYNCHRONIZER

Fig. 232 3/4 Synchro Snap Ring

1 - SNAP RING
2 - 3/4 SYNCHRONIZER

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INPUT SHAFT (Continued)

(7) Install 4th gear blocker ring (Fig. 233).

(8) Install 4th gear and needle bearing (Fig. 234)

(Fig. 235).

(9) Install 5th gear and press into position using

installer 8481 (Fig. 236).

Fig. 233 4th Gear Blocker Ring

1 - 4th GEAR BLOCKER RING

Fig. 234 4th Gear Needle Bearing Removal/

Installation

1 - 4TH GEAR NEEDLE BEARING

Fig. 235 4th Gear Removal/Installation

1 - 4TH GEAR
2 - NEEDLE BEARING

Fig. 236 5th Gear Installation

1 - ARBOR PRESS RAM
2 - INSTALLER 8481
3 - 5TH GEAR

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INPUT SHAFT (Continued)

(10) Install NEW 5th gear nut and torque to 262

N·m (193 ft. lbs.) using wrench 8478 (Fig. 237).

(11) Stake 5th Gear nut in four (4) places as follows:

(a) Install staking tool 8479 to 5th gear nut.
(b) Tighten upper thumb screw by hand (Fig.

238).

(c) Tighten two (2) side thumb screws by hand.
(d) Tighten both staking screws until they bot-

tom on tool body (Fig. 239).

(e) Loosen staking screws and thumb screws.

Remove tool and visually inspect stake (Fig. 240).

(f) Remove tool, rotate 90°, and repeat process to

stake in four (4) places.

NOTE: The input shaft sealed roller bearing and
snap ring do not get installed until transaxle assem-
bly to facilitate installation of the reverse idler gear
mechanism.

Fig. 238 Staking Tool Set-Up

1 - STAKING TOOL 8479
2 - THUMB SCREWS (3)

Fig. 237 5th Gear Nut Removal/Installation

1 - WRENCH 8478
2 - 5TH GEAR NUT

Fig. 239 Tighten Stake Screws

1 - STAKING TOOL 8479

Fig. 240 5th Gear Nut Stake (Four Places)

1 - STAKE

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INPUT SHAFT (Continued)

INTERMEDIATE SHAFT

DESCRIPTION

The intermediate shaft assembly (Fig. 241) is part

of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated pinion gear, and consists of the following com-
ponents:

• Intermediate Shaft

• 1st Speed Gear

• 2nd Speed Gear

• 3/4 Cluster Gear

• 5th Speed Gear

• Reverse Gear

• 1/2 Synchronizer

• 5/R Synchronizer
The intermediate shaft is supported by a caged

roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.

Fig. 241 Intermediate Shaft Assembly

1 - INTERMEDIATE SHAFT

12 - THRUST WASHER

2 - ROLLER BEARING

13 - NEEDLE BEARING

3 - SNAP RING

14 - REVERSE GEAR

4 - NEEDLE BEARING

15 - SNAP RING

5 - 1ST SPEED GEAR

16 - 5/R SYNCHRO

6 - SNAP RING

17 - 5TH SPEED GEAR

7 - 2ND SPEED GEAR

18 - NEEDLE BEARING

8 - 3/4 CLUSTER GEAR

19 - NEEDLE BEARING

9 - SNAP RING

20 - 1/2 SYNCHRO

10 - SNAP RING

21 - THRUST BEARING

11 - SEALED ROLLER BEARING

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T850 MANUAL TRANSAXLE

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