Chrysler Town, Dodge Caravan. Manual — part 372
(5) Remove extension housing-to-case and differen-
tial cover bolts (Fig. 32).
(6) Place transaxle with bellhousing surface down.
(7) Remove backup lamp switch (Fig. 33).
(8) Remove end plate (Fig. 34).
(9) Set up lifting bar (tool 8489) as shown in (Fig.
35).
(10) Lift up on bar (input shaft bearing side) and
remove input shaft bearing snap ring.
(11) Lift up on bar (intermediate shaft side) and
remove intermediate shaft bearing snap ring.
Fig. 32 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
Fig. 33 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 34 End Plate Bolts
1 - BOLT (11)
Fig. 35 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
21 - 38
T850 MANUAL TRANSAXLE
RS
T850 MANUAL TRANSAXLE (Continued)
(12) Remove lifting bar 8489.
(13) Remove end cover-to-case bolts (12) (Fig. 36).
(14) Remove end cover from transaxle (Fig. 37).
(15) Remove 3/4 shift rail bushing from end cover
using slide hammer C-3752 and remover 6786 (Fig.
38).
(16) Remove reverse idler bolt (Fig. 39). Remove
reverse idler gear, washers, and shaft upon geartrain
removal.
Fig. 36 End Cover Bolts
1 - BOLT (12)
Fig. 37 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
Fig. 38 3/4 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
Fig. 39 Reverse Idler Shaft Bolt
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T850 MANUAL TRANSAXLE
21 - 39
T850 MANUAL TRANSAXLE (Continued)
(17) Remove 1-2/5-R shift rail (Fig. 40).
(18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 41).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 41).
(21) Remove lifting bar from geartrain.
NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(22) Reinstall and torque extension housing and
measure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
(23) Remove differential cover bolts.
(24) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(25) Remove extension housing.
(26) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 42).
Fig. 40 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 41 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 42 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
21 - 40
T850 MANUAL TRANSAXLE
RS
T850 MANUAL TRANSAXLE (Continued)
(27) Remove differential chip collector magnet and
clean (Fig. 43). Magnet is adhered with RTV, and
may require force to remove.
(28) Remove intermediate shaft bearing race with
puller 8472 (Fig. 44).
(29) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 45).
(30) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 46).
Fig. 43 Differential Magnet
1 - MAGNET
Fig. 44 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 45 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
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T850 MANUAL TRANSAXLE
21 - 41
T850 MANUAL TRANSAXLE (Continued)
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