2001 CHRYSLER VOYAGER differential

(21) Install battery thermal shield and clutch cable
eyelet (LHD only) (Fig. 99). Verify proper clutch cable
routing (LHD models). Cable should be routed over
guide, through eyelet, and around coolant bottle and
wiring harness.
(22) Connect battery cables.
(23) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
SPECIFICATIONS
SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.46
2nd 2.07 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.53
Overall Top Gear 3.12 2.66
Fig. 99 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RGT850 MANUAL TRANSAXLE21a-37
T850 MANUAL TRANSAXLE (Continued)

INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear 0.66-1.84 mm (0.026-0.072 in.)
2nd Gear 0.66-1.84 mm (0.026-0.072 in.)
5th Gear 0.86-1.54 mm (0.034-0.061 in.)
Reverse 0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear 0.091-0.828 mm (0.004-0.033 in.)
2nd Gear 0.051-0.787 mm (0.002-0.031 in.)
5th Gear 0.102-0.762 mm (0.004-0.030 in.)
Reverse 0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION METRIC STANDARD
Differential Turning Torque 2.3-3.4 N´m 20-30 in. lbs.
Side Gear End Play (each side) 0.025-0.152 mm 0.001-0.006 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential Cover-to-Case 54 40 Ð
Bolt, End Cover-to-Case 28 Ð 250
Bolt, End Cover Plate-to-Cover 28 Ð 250
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Reverse Idler Shaft-to-Case 54 40 Ð
Bolt, Ring Gear-to-Differential Case 95 70 Ð
Bolt, Shift Cover-to-Case 28 Ð 250
Nut, 5th Gear-to-Input Shaft 200 148 Ð
Plug, Drain 23 17 Ð
Screw, Input Bearing Retainer 12 Ð 105
Switch, Back-Up Lamp 23 17 Ð
Vent 7 Ð 60
21a - 38 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)

AXLE SEALS
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove one or both front halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
(3) Using a suitable screwdriver, remove one or
both axle seals (Fig. 100).
INSTALLATION
(1) Using driver handle C-4171 and installer 8476,
install axle seals into position (Fig. 101) (Fig. 102).
(2) Install one or both front halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(3) Check transaxle fluid level and adjust if neces-
sary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/FLUID - STANDARD PROCEDURE)
(4) Lower vehicle.
Fig. 100 Axle Seal Removal (Extension Housing
Side Shown)
1 - SCREWDRIVER
2 - AXLE SEAL
3 - EXTENSION HOUSING
Fig. 101 Axle Seal Installation
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
Fig. 102 Axle Seal Installation (Extension Housing
Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
21a - 42 T850 MANUAL TRANSAXLERG

BACK-UP LAMP SWITCH
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect back-up lamp switch connector.
(3) Remove back-up lamp switch (Fig. 103).
INSTALLATION
(1) Install back-up lamp switch (Fig. 103) and
torque to 23 N´m (17 ft. lbs.).
(2) Connect back-up lamp switch connector.
(3) Lower vehicle.
DIFFERENTIAL
DESCRIPTION
The T850 differential is a conventional open
design. It consists of a ring gear and a two-piece dif-
ferential case. The differential case contains the pin-
ion and side gears, three floating pinion shafts, and a
pinion shaft retaining ring (Fig. 104). The differential
case is supported in the transaxle by tapered roller
bearings.
OPERATION
The differential assembly is driven by the interme-
diate shaft via the ring gear. The ring gear drives the
differential case, and the case drives the halfshafts
through the differential gears. The differential pinion
and side gears are supported in the case by pinion
shafts and thrust washers. Differential pinion and
side gears make it possible for front wheels to rotate
at different speeds while cornering.
Fig. 103 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 104 Differential Assembly
1 - RING GEAR
2 - SUPPORT PLATE
3 - SIDE GEAR (2)
4 - PINION GEAR (4)
5 - BOLT (12)
6 - PINION SHAFT (2-SHORT)
7 - PINION SHAFT (1-LONG)
8 - THRUST WASHER (2)
9 - RETAINING RING
10 - DIFFERENTIAL CASE
RGT850 MANUAL TRANSAXLE21a-43

DISASSEMBLY
(1) Remove differential side bearings:
(a) Install button 8491-1 to differential case (Fig.
105).
(b) Set up Tool 5048 (5048-1, -4, -6) as shown in
(Fig. 106).
(c) Remove differential side bearing (Fig. 107).
Same procedure/tools work for both sides.
(2) Remove ring gear-to-case bolts (Fig. 108) and
remove ring gear.
Fig. 105 Tool 8491
1 - TOOL 8491
Fig. 106 Puller 5048
1 - 5048-1 FORCING SCREW
2 - 5048-4 COLLETS
3 - 5048-6 SLEEVE
Fig. 107 Differential Side Bearing Removal
1 - TOOL 5048
Fig. 108 Ring Gear-to-Differential Case Bolts
1 - BOLT (12)
2 - DIFFERENTIAL SUPPORT
3 - RING GEAR
21a - 44 T850 MANUAL TRANSAXLERG
DIFFERENTIAL (Continued)

(3) Using three ring gear bolts as forcing screws
(Fig. 109), separate differential support from case
(Fig. 110).(4) Remove side gear thrust washer (Fig. 111).
(5) Remove side gear (Fig. 112).
Fig. 109 Separate Differential Case Halves
1 - BOLT (3)
2 - DIFFERENTIAL CASE
3 - DIFFERENTIAL SUPPORT
Fig. 110 Differential Support Plate
1 - DIFFERENTIAL SUPPORT PLATE
2 - DIFFERENTIAL CASE
Fig. 111 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
2 - DIFFERENTIAL SIDE GEAR
Fig. 112 Differential Side Gear
1 - DIFFERENTIAL SIDE GEAR
RGT850 MANUAL TRANSAXLE21a-45
DIFFERENTIAL (Continued)

(6) Remove long pinion shaft (Fig. 113).
(7) Remove both short pinion shafts (Fig. 114).(8) Remove pinion shaft retainer (Fig. 115).
(9) Remove four pinion gears and thrust washers
(Fig. 116).
Fig. 113 Long Pinion Shaft
1 - PINION SHAFT (LONG)
Fig. 114 Short Pinion Shaft (2)
1 - PINION SHAFT (SHORT (2))
Fig. 115 Pinion Shaft Retaining Ring
1 - RETAINING RING
Fig. 116 Pinion Gear and Thrust Washer
1 - THRUST WASHER (4)
2 - PINION GEAR (4)
21a - 46 T850 MANUAL TRANSAXLERG
DIFFERENTIAL (Continued)

(10) Remove side gear (Fig. 117).
(11) Remove side gear thrust washer (Fig. 118).ASSEMBLY
(1) Install side gear thrust washer (Fig. 119).
(2) Install differential side gear (Fig. 120).
Fig. 117 Differential Side Gear
1 - DIFFERENTIAL SIDE GEAR
Fig. 118 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
Fig. 119 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
Fig. 120 Differential Side Gear
1 - DIFFERENTIAL SIDE GEAR
RGT850 MANUAL TRANSAXLE21a-47
DIFFERENTIAL (Continued)