Chrysler Town, Dodge Caravan. Manual — part 389
(22) Remove 1st gear from shaft (Fig. 248).
(23) Remove 1st gear needle bearing (Fig. 249).
(24) Remove
intermediate
shaft
roller
bearing
snap ring (Fig. 250).
(25) Press intermediate shaft out of roller bearing
supported by bearing splitter P-334 (Fig. 251).
Roller bearing is not re-usable once removed. It
is necessary to install a new roller bearing
upon re-assembly.
Fig. 248 1st Gear Removal
1 - 1ST GEAR
Fig. 249 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 250 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 251 Intermediate Shaft Roller Bearing Removal
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - ROLLER BEARING
4 - BEARING SPLITTER P-334
21 - 106
T850 MANUAL TRANSAXLE
RS
INTERMEDIATE SHAFT (Continued)
ASSEMBLY
NOTE: Depending on date of transaxle manufacture,
some intermediate shafts will utilize a needle bear-
ing under 2nd and 5th Speed Gears.
NOTE: Do not re-use snap rings when servicing the
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.
NOTE: When installing 1/2 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 252) for intermediate shaft
assembly reference.
Fig. 252 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT
10 - SNAP RING
2 - ROLLER BEARING
11 - SEALED ROLLER BEARING
3 - SNAP RING
12 - THRUST WASHER
4 - NEEDLE BEARING
13 - NEEDLE BEARING
5 - 1ST SPEED GEAR
14 - REVERSE GEAR
6 - SNAP RING
15 - SNAP RING
7 - 2ND SPEED GEAR
16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR
17 - 5TH SPEED GEAR
9 - SNAP RING
18 - 1/2 SYNCHRO
RS
T850 MANUAL TRANSAXLE
21 - 107
INTERMEDIATE SHAFT (Continued)
(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 253).
(2) Install intermediate shaft roller bearing snap
ring (Fig. 254).
(3) Install 1st gear roller bearing to intermediate
shaft (Fig. 255).
(4) Install 1st gear to intermediate shaft (Fig.
256).
(5) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 257).
(6) Install intermediate shaft to synchro assembly
on fixture (Fig. 258). When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal. Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture.
Fig. 253 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
Fig. 254 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 255 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 256 1st Gear Installation
1 - 1ST GEAR
21 - 108
T850 MANUAL TRANSAXLE
RS
INTERMEDIATE SHAFT (Continued)
(7) Install NEW 1/2 synchro snap ring (Fig. 259).
(8) Install 2nd gear blocker ring (Fig. 260).
Fig. 257 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
Fig. 258 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 259 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 260 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
RS
T850 MANUAL TRANSAXLE
21 - 109
INTERMEDIATE SHAFT (Continued)
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