Chrysler Town, Dodge Caravan. Manual — part 367
INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 47). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.
(5) Apply Mopar
t Gasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N·m (250 in. lbs.)
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
Fig. 45 Input Shaft and Ring Gear Removal
1 - POWER TRANSFER UNIT
2 - RING GEAR
Fig. 46 Seal Removal
1 - POWER TRANSFER UNIT
2 - SPECIAL TOOL
7794–A
Fig. 47 Seal Installation
1 - HAMMER
2 - SPECIAL TOOL
C-4171
3 - SPECIAL TOOL
C-4657
4 - POWER TRANSFER UNIT
21 - 18
POWER TRANSFER UNIT
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INPUT SHAFT SEAL (Continued)
OUTER HALF SHAFT SEAL
REMOVAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Lift vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove seal with a chisel and hammer (Fig.
48).
INSTALLATION
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Clean and inspect seal area.
(2) Install new seal with seal installer MD998334
(Fig. 49).
(3) Reinstall right front half shaft.
(4) Check and fill fluids as required.
REAR COVER O-RING
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear cover retaining bolts (Fig. 50).
Fig. 48 Seal Removal
1 - HAMMER
2 - CHISEL
3 - SEAL
4 - POWER TRANSFER UNIT
Fig. 49 Seal Installation
1 - BEARING
2 - SNAP RING PLIERS
3 - BEARING SNAP RING
Fig. 50 Rear Cover Bolts
1 - OUTPUT FLANGE SEAL
2 - REAR COVER
3 - OUTPUT SHAFT
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POWER TRANSFER UNIT
21 - 19
(3) Index rear cover to the case for later reassem-
bly (Fig. 51).
(4) Pull rear cover out of the P.T.U. case (Fig. 52).
(5) Remove rear cover O-Ring (Fig. 53).
INSTALLATION
(1) To install, reverse removal procedure.
Fig. 51 Mark Rear Cover
1 - REAR COVER
2 - OUTPUT SHAFT
3 - PAINT MARK
Fig. 52 Rear Cover Removal
1 - POWER TRANSFER UNIT ASSEMBLY
2 - REAR COVER
3 - O-RING
Fig. 53 O-Ring Removal
1 - REAR COVER
2 - PINION GEAR
3 - O-RING
21 - 20
POWER TRANSFER UNIT
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REAR COVER O-RING (Continued)
T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page
page
T850 MANUAL TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - COMMON
. . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . 56
SPECIAL TOOLS - T850 TRANSAXLE
AXLE SEALS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . 61
BACK-UP LAMP SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . 62
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FLUID
STANDARD PROCEDURE - FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
STANDARD PROCEDURE - FLUID DRAIN
AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
GEARSHIFT BOOT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
. . . . . . . . . . . . . . . . . . . . . . . . . 73
GEARSHIFT CABLE - CROSSOVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
. . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . 79
GEARSHIFT CABLE - SELECTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . . . . . . . . 84
GEARSHIFT KNOB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
. . . . . . . . . . . . . . . . . . . . . . . . . 87
GEARSHIFT MECHANISM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
. . . . . . . . . . . . . . . . . . . . . . . . . 89
INPUT SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
INTERMEDIATE SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . 100
. . . . . . . . . . . . . . . . . . . . . . . . 100
. . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SHIFT COVER
. . . . . . . . . . . . . . . . . . . . . . . . 113
SHIFT FORK AND SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . 113
SYNCHRONIZER
. . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . . . . . . . . . . . . . . 114
VEHICLE SPEED SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
. . . . . . . . . . . . . . . . . . . . . . . . 115
T850 MANUAL TRANSAXLE
DESCRIPTION
The NV T850 5-speed transaxle (Fig. 1) is a con-
stant-mesh manual transaxle that is synchronized in
all gear ranges, including reverse.
The transaxle consists of three major sub-assem-
blies: the input shaft, intermediate shaft, and differ-
ential assembly. The transaxle shift system consists
of a mechanical shift cover, rails, forks, and cables.
The unique design of this shift system provides a
higher mechanical advantage, resulting in less fric-
tion and lower shift cable loads for smoother, more
positive operation.
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T850 MANUAL TRANSAXLE
21 - 21
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