Chrysler Town, Dodge Caravan. Manual — part 386
(3) Remove
input
bearing.
Place
input
shaft
assembly onto arbor press table, with the input bear-
ing supported by bearing splitter (Fig. 207). Using
adapter 8486-4, press bearing off of shaft, while
helper supports shaft to prevent dropping.
(4) Place input shaft assembly back into fixture
8487. Secure fixture to bench with fasteners, or
secure to bench vise.
NOTE: 5th gear nut is staked to the shaft. If neces-
sary, grind stake area to ease removal, but use care
not to contact gear.
(5) Remove 5th gear nut with wrench 8478 (Fig.
208). Discard nut and use a new one upon assembly.
(6) Remove 5th gear with arbor press and bearing
splitter.
(7) Remove
4th
gear
and
needle
bearing
(if
equipped) (Fig. 209).
Fig. 206 Input Bearing Snap Ring Removal
1 - SNAP RING
2 - INPUT BEARING
Fig. 207 Input Bearing Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - INPUT BEARING
4 - BEARING SPLITTER
Fig. 208 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
Fig. 209 4th Gear Removal/Installation
1 - 4th GEAR
21 - 94
T850 MANUAL TRANSAXLE
RS
INPUT SHAFT (Continued)
(8) Remove 4th gear blocker ring (Fig. 210).
(9) Remove 3/4 synchronizer snap ring (Fig. 211).
Discard and replace with new snap ring upon assem-
bly.
(10) Remove 3/4 synchronizer (Fig. 212).
(11) Remove 3rd gear blocker ring (Fig. 213).
(12) Remove 3rd gear and needle bearing (if
equipped) (Fig. 214).
(13) Inspect third gear thrust washer for signs of
excessive wear. To replace, drive off of input shaft
with suitable drift and hammer.
Fig. 210 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 211 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 212 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 213 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
RS
T850 MANUAL TRANSAXLE
21 - 95
INPUT SHAFT (Continued)
ASSEMBLY
NOTE: Depending on date of manufacture, some
input shafts will utilize a needle bearing under the
3rd and 4th Speed Gears.
NOTE: When servicing the input shaft assembly, all
snap rings MUST be replaced with new ones upon
assembly. 5th gear nut must also be replaced.
NOTE: When installing 3/4 synchronizer hub to
shaft, make sure to align oil slots on synchronizer
hub face with oil hole in the shaft splined hub jour-
nal.
NOTE: Refer to (Fig. 215) for input shaft assembly
reference.
Fig. 215 Input Shaft Assembly
1 - INPUT SHAFT
6 - 5TH GEAR NUT
2 - THRUST WASHER
7 - SNAP RING
3 - 3RD GEAR
8 - INPUT BEARING (SEALED)
4 - 4TH GEAR
9 - SNAP RING
5 - 5TH GEAR
10 - 3/4 SYNCHRONIZER
Fig. 214 3rd Gear Removal/Installation
1 - 3RD GEAR
21 - 96
T850 MANUAL TRANSAXLE
RS
INPUT SHAFT (Continued)
(1) Install input shaft into fixture 8487.
(2) Install thrust washer if removed upon disas-
sembly.
(3) Install
3rd
gear
and
needle
bearing
(if
equipped) (Fig. 216).
(4) Install 3rd gear blocker ring (Fig. 217).
(5) Install 3/4 synchronizer (Fig. 218). When
installing 3/4 synchronizer hub to shaft, make
sure to align oil slots on synchronizer hub face
with oil hole in the shaft splined hub journal.
(6) Install NEW 3/4 synchronizer snap ring (Fig.
219).
Fig. 216 3rd Gear Removal/Installation
1 - 3RD GEAR
Fig. 217 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 218 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 219 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
RS
T850 MANUAL TRANSAXLE
21 - 97
INPUT SHAFT (Continued)
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