Chrysler Town, Dodge Caravan. Manual — part 380
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER
SHIM THICKNESS
METRIC (MM)
STANDARD (STD)
4659242
0.50
0.0197
4659243
0.54
0.0213
4659247
0.58
0.0228
4659248
0.62
0.0244
4659249
0.66
0.0260
4659250
0.70
0.0276
4659251
0.74
0.0291
4659252
0.78
0.0307
4659253
0.82
0.0322
4659254
0.86
0.0339
4659255
0.90
0.0354
4659256
0.94
0.0370
4659257
0.98
0.0386
4659258
1.02
0.0402
4659259
1.06
0.0418
4659260
1.10
0.0434
4659261
1.14
0.0449
4659262
1.18
0.0465
4659263
1.22
0.0481
4659264
1.26
0.0497
4659265
1.30
0.0512
4659266
1.34
0.0528
4659267
1.38
0.0544
4659268
1.42
0.0560
4659269
1.46
0.0575
4659270
1.50
0.0591
4659271
1.54
0.0607
4659272
1.58
0.0623
4659273
1.62
0.0638
4659274
1.66
0.0654
4659275
1.70
0.0670
4659283
2.02
0.0796
4659284
2.06
0.0812
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
END PLAY
Measure side gear end play: Insert feeler gauges
180° apart between differential side gear and thrust
washer as shown in (Fig. 124). Measurement taken
here applies to both sides. Side gear end play should
be between 0.025-0.152 mm (0.001-0.006 in.). If clear-
ance is greater than 0.152 mm (0.006 in.), install a
thicker thrust washer (both sides). If clearance is less
than 0.025 mm (0.001), install a thinner thrust
washer (both sides). Refer to (Fig. 125) for available
side gear shim thicknesses.
21 - 70
T850 MANUAL TRANSAXLE
RS
DIFFERENTIAL (Continued)
If end play measurement indicates a thrust washer
change is necessary, the differential must be disas-
sembled. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/DIFFERENTIAL - DISASSEMBLY)
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
NOTE: For proper fluid level check intervals, (Refer
to LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopar
t
ATF+4. Use of substitute fluids may result in
improper transaxle operation and/or failure.
(1) Raise vehicle on hoist.
(2) Remove transaxle fill plug (Fig. 126).
(3) Inspect fluid level. Fluid should be within 3/16”
below fill hole. Add Mopar
t ATF+4 as neccessary.
(4) Install fill plug, ensuring it is properly seated.
(5) Lower vehicle.
STANDARD PROCEDURE - FLUID DRAIN AND
FILL
NOTE: For proper fluid change intervals, (Refer to
LUBRICATION
&
MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopar
t
ATF+4. Use of substitute fluids may result in
improper transaxle operation and/or failure.
Fig. 124 Side Gear End Play Measurement
1 - FEELER GAUGE
Fig. 125 Available Side Gear Thrust Washers
1 - (PLAIN) 0.79-0.84 mm (0.031-0.033 in.)
2 - ( TRIANGLE) 0.91-0.97 mm (0.036-0.038 in.)
3 - (SQUARE) 1.04-1.10 mm (0.041-0.043 in.)
4 - (DIAMOND) 1.17-1.22 mm (0.046-0.048 in.)
Fig. 126 Transaxle Fill Plug
1 - FILL PLUG
2 - END COVER
RS
T850 MANUAL TRANSAXLE
21 - 71
DIFFERENTIAL (Continued)
FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 127) and
drain fluid into suitable container.
(3) Install drain plug and torque to 23 N·m (17 ft.
lbs.).
FLUID FILL
(1) Remove transaxle fill plug (Fig. 128).
(2) Add 2.4-2.7L (2.5-2.9 qts.) of Mopar
t ATF+4
until fluid is within 3/16” below fill hole.
(3) Install fill plug, ensuring it is properly seated.
(4) Lower vehicle.
GEARSHIFT BOOT
REMOVAL
(1) Remove gearshift knob by pushing down and
rotating
1
⁄
4
-turn clockwise (Fig. 129).
(2) Remove gearshift boot from center console by
disengaging three (3) retaining clips (Fig. 130).
Fig. 127 Transaxle Drain Plug
1 - TRANSAXLE DRAIN PLUG
2 - DIFFERENTIAL COVER
Fig. 128 Transaxle Fill Plug
1 - FILL PLUG
2 - END COVER
Fig. 129 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 130 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
21 - 72
T850 MANUAL TRANSAXLE
RS
FLUID (Continued)
INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 130).
(2) Install gearshift knob (Fig. 129). Orient shift
pattern
1
⁄
4
-turn clockwise, press down, and rotate
1
⁄
4
-
turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
GEARSHIFT CABLE -
CROSSOVER
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1
⁄
4
-turn clock-wise (Fig. 131).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 132).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
133).
Fig. 131 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 132 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 133 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
RS
T850 MANUAL TRANSAXLE
21 - 73
GEARSHIFT BOOT (Continued)
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