Chrysler Town, Dodge Caravan. Manual — part 390
(9) Install 2nd gear friction cone (Fig. 261).
(10) Install 2nd gear reactor ring (Fig. 262).
(11) Install
2nd
gear
and
needle
bearing
(if
equipped) to intermediate shaft (Fig. 263).
(12) Press 3/4 cluster gear onto intermediate shaft
using cup 8481 (Fig. 264).
Fig. 261 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 262 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 263 2nd Gear
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
Fig. 264 Install 3/4 Cluster Gear using Tool 8481
1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR
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T850 MANUAL TRANSAXLE
RS
INTERMEDIATE SHAFT (Continued)
(13) Install NEW 3/4 cluster gear snap ring (Fig.
265).
(14) Install
5th
gear
and
needle
bearing
(if
equipped) to intermediate shaft (Fig. 266).
(15) Install 5th gear blocker ring to synchronizer
(Fig. 267).
(16) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 268). When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
Fig. 265 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 266 5th Gear Installation
1 - 5th GEAR
Fig. 267 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 268 Install 5/R Synchro and 5th Blocker Ring to
5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
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T850 MANUAL TRANSAXLE
21 - 111
INTERMEDIATE SHAFT (Continued)
(17) Install NEW 5/R synchro snap ring (Fig. 269).
(18) Install reverse gear blocker ring (Fig. 270).
(19) Install reverse gear needle bearing (Fig. 271).
(20) Install reverse gear to intermediate shaft.
(21) Install intermediate shaft sealed roller bear-
ing and thrust washer using installer 8482 (Fig. 272).
(22) Install NEW intermediate shaft sealed bear-
ing snap ring (Fig. 273).
Fig. 269 5/R Synchro Snap Ring
1 - SNAP RING
Fig. 270 Reverse Gear Blocker Ring
1 - REVERSE BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 271 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 272 Sealed Roller Bearing Installatiion
1 - ARBOR PRESS
2 - REMOVER/INSTALLER 8482
3 - SEALED ROLLER BEARING
4 - THRUST WASHER
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T850 MANUAL TRANSAXLE
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INTERMEDIATE SHAFT (Continued)
SHIFT COVER
DESCRIPTION
The shift cover assembly (Fig. 274) (Fig. 275) is
operated by the gearshift crossover and selector
cables, and operates the shift fork/shaft system. It
consists of crossover and selector lever mechanisms,
transaxle vent, a main shift selector shaft, and the
5-R blockout mechanism. The shift cover is only ser-
viced as an assembly.
SHIFT FORK AND SHAFT
DESCRIPTION
The T850 utilizes a unique shift fork and shaft
arrangement consisting of three shift forks and two
shafts as shown in (Fig. 276). This system is oper-
ated by the shift cover assembly, which combined
with a unique gearshift cable design, offers a higher
mechanical advantage over traditional shift systems.
This arrangement results in less friction and lower
shift cable loads for smoother, more positive opera-
tion. The shift fork assemblies are constructed of
brass, float about the shafts with the aid of needle
bearings, and are serviced only as fork/bearing
assemblies.
Fig. 273 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
Fig. 274 Shift Lever Identification
1 - SHIFT COVER ASSEMBLY
2 - VENT
3 - CROSSOVER LEVER
4 - SELECTOR LEVER
Fig. 275 Shift Cover Assembly Components
1 - SHAFT
2 - 5-R BLOCKOUT PIN/CAM
3 - SHIFT SELECTOR
4 - SHIFT BLOCKER
5 - SELECTOR LEVER/DETENT
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T850 MANUAL TRANSAXLE
21 - 113
INTERMEDIATE SHAFT (Continued)
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