Chrysler Town, Dodge Caravan. Manual — part 373
ASSEMBLY
NOTE: When assembling this transaxle, always use
NEW snap rings.
NOTE: Before assembling transaxle, differential
turning torque must be measured and adjusted.
(Refer to 21 - TRANSMISSION/TRANSAXLE/MANU-
AL/DIFFERENTIAL - ADJUSTMENTS). Differential
turning torque must be measured with geartrain out
of case.
(1) Install input shaft bearing using an arbor press
and remover/installer 8474 (Fig. 47).
(2) Install
shift
shaft
bushing
to
case
using
installer 8475 (Fig. 48).
Fig. 46 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
Fig. 47 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 48 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
21 - 42
T850 MANUAL TRANSAXLE
RS
T850 MANUAL TRANSAXLE (Continued)
(3) Install intermediate shaft bearing race to case
with an arbor press, driver handle C-4171, and
installer 8471 (Fig. 49). Press until installer 8471
bottoms on transaxle case.
NOTE: If input shaft assembly was not disassem-
bled, it is necessary to remove input shaft sealed
ball bearing before assembling transaxle. (Refer to
21 - TRANSMISSION/TRANSAXLE/MANUAL/INPUT
SHAFT - DISASSEMBLY)
(4) Install
assembled
input
and
intermediate
shafts to fixture 8487 (Fig. 50).
(5) Install shift forks and 3/4 rail assembly to
geartrain as shown in (Fig. 51).
NOTE: Before installing geartrain, make sure that
input shaft sealed roller bearing is not installed,
otherwise reverse idler assembly installation will be
difficult. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/INPUT SHAFT - DISASSEMBLY)
Fig. 49 Install Intermediate Shaft Bearing Race
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - INSTALLER 8471
4 - INTERMEDIATE SHAFT BEARING RACE
Fig. 50 Install Geartrain to Fixture 8487
1 - INTERMEDIATE SHAFT
2 - INPUT SHAFT
2 - FIXTURE 8487
RS
T850 MANUAL TRANSAXLE
21 - 43
T850 MANUAL TRANSAXLE (Continued)
(6) Install lifting bar 8489 to geartrain. Install
geartrain to case. When installing geartrain to
case, use care not to damage bearing surfaces.
(7) Remove lifting bar 8489 from geartrain.
(8) Install shift 1/2-5/R rail as shown in (Fig. 52).
(9) Install reverse idler shaft into position (Fig.
53). Install and torque shaft-to-case bolt to 54 N·m
(40 ft. lbs.).
(10) Install reverse idler gear bearing (Fig. 54).
(11) Install reverse idler gear with hub down as
shown in (Fig. 55).
(12) Install flat washer (Fig. 56).
(13) Install wave washer (Fig. 57).
Fig. 51 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 52 Shift Rail Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 53 Install Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
2 - BOLT
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T850 MANUAL TRANSAXLE
RS
T850 MANUAL TRANSAXLE (Continued)
Fig. 54 Install Reverse Idler Gear Bearing
1 - NEEDLE BEARING
2 - REVERSE IDLER SHAFT
Fig. 55 Install Reverse Idler Gear
1 - REVERSE IDLER GEAR
Fig. 56 Install Flat Washer
1 - FLAT WASHER
Fig. 57 Install Wave Washer
1 - WAVE WASHER
RS
T850 MANUAL TRANSAXLE
21 - 45
T850 MANUAL TRANSAXLE (Continued)
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