2001 CHRYSLER VOYAGER differential

(3) Install four (4) pinion gears and thrust washers
(Fig. 121).
(4) Install pinion shaft retaining ring (Fig. 122).(5) Install two (2) short pinion shafts (Fig. 123).
(6) Install one (1) long pinion shaft (Fig. 124).
(7) Install differential side gear.
(8) Install side gear thrust washer (Fig. 125).
(9) Install differential support plate. Align support
plate to differential case with alignment pins 8470
(Fig. 126).
Fig. 121 Pinion Gear and Thrust Washer
1 - THRUST WASHER (4)
2 - PINION GEAR (4)
Fig. 122 Pinion Shaft Retaining Ring
1 - RETAINING RING
Fig. 123 Short Pinion Shaft (2)
1 - PINION SHAFT (SHORT (2))
Fig. 124 Long Pinion Shaft
1 - PINION SHAFT (LONG)
21a - 48 T850 MANUAL TRANSAXLERG
DIFFERENTIAL (Continued)

(10) Install thrust buttons 8491 to both bearing
journals and press halves together using an arbor
press (Fig. 127).
(11) Install ring gear into position, start three ring
gear-to-differential case bolts by hand (120É apart),
and install alignment pins 8470 (Fig. 128).
(12) Torque three ring gear bolts to draw ring gear
into position. Remove alignment pins, install remain-ing ring gear-to-differential case bolts and torque to
95 N´m (70 ft. lbs.) (Fig. 129).
(13) Install tapered roller bearings using installer
8473 and an arbor press (Fig. 130). Insert button
8491 on opposite journal to protect journal and/or
bearing during press operation. Repeat the same
operation on opposite side.
Fig. 125 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
2 - DIFFERENTIAL SIDE GEAR
Fig. 126 Align Differential Support to Case
1 - ALIGNMENT PIN 8470
2 - DIFFERENTIAL SUPPORT PLATE
3 - DIFFERENTIAL CASE
Fig. 127 Installing Differential Support
1 - ARBOR PRESS
2 - BUTTON 8491
3 - DIFFERENTIAL SUPPORT PLATE
4 - ALIGNMENT PIN 8470
5 - DIFFERENTIAL CASE
Fig. 128 Ring Gear Alignment/Installation
1 - ALIGNMENT PIN 8470
2 - BOLT
RGT850 MANUAL TRANSAXLE21a-49
DIFFERENTIAL (Continued)

(14) Measure and verify differential side gear end
play. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/DIFFERENTIAL - ADJUSTMENTS).
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE
NOTE: Differential turning torque should only be
measured with the geartrain out of the transaxle. If
measurement is taken with transaxle assembled, an
inaccurate measurement will result.
NOTE: All differential cover-to-case bolts and exten-
sion housing-to-case bolts must be installed and
torqued to obtain accurate measurement.
(1) If transaxle is assembled, remove geartrain
and leave differential in place. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL - DISASSEMBLY)
(2) Install differential cover and torque differential
cover-to-case bolts to 54 N´m (40 ft. lbs.).
(3) Install extension housing and torque extension
housing-to-case bolts to 28 N´m (250 in. lbs.).
(4) Place transaxle on work bench so axle center-
line is parallel to the ground.
(5) Install turning torque tool C-4995 to differen-
tial at side opposite extension housing.
(6) Using in. lb./N´m dial indicator, rotate differen-
tial case multiple times and record measurement
(Fig. 131). Differential turning torque should be
within 2.3-3.4 N´m (20-30 in. lbs.). Refer to shim
chart for proper shim selection. If turning torque
measured is less than 2.3 N´m (20 in. lbs.), install a
thicker shim. If turning torque measured is greater
than 3.4 N´m (30 in. lbs.), install a thinner shim.
Fig. 129 Ring Gear-to-Differential Case Bolts
1 - BOLT (12)
2 - DIFFERENTIAL SUPPORT
3 - RING GEAR
Fig. 130 Differential Side Bearing Installation
1 - ARBOR PRESS
2 - INSTALLER 8473
3 - BEARING
4 - BUTTON 8491
Fig. 131 Differential Turning Torque Measurement
1 - DIAL TORQUE WRENCH
2 - TOOL C-4995
21a - 50 T850 MANUAL TRANSAXLERG
DIFFERENTIAL (Continued)

DIFFERENTIAL BEARING SHIM CHART
PART NUMBERSHIM 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
RGT850 MANUAL TRANSAXLE21a-51
DIFFERENTIAL (Continued)

ADJUSTMENT - DIFFERENTIAL SIDE GEAR
END PLAY
Measure side gear end play: Insert feeler gauges
180É apart between differential side gear and thrust
washer as shown in (Fig. 132). 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. 133) for available
side gear shim thicknesses.
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 - FLUID LEVEL
CHECK
NOTE: For proper fluid level check intervals, (Refer
to LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
The fluid required in this transaxle is Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
(1) Raise vehicle on hoist.
(2) Remove transaxle fill plug (Fig. 134).(3) Inspect fluid level. Fluid should be within 1/8º
below fill hole. Add MopartATF+4 (Automatic Trans-
mission FluidÐType 9602) as neccessary.
(4) Install fill plug, ensuring it is properly seated.
(5) Lower vehicle.
Fig. 132 Side Gear End Play Measurement
1 - FEELER GAUGE
Fig. 133 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. 134 Transaxle Fill Plug
1 - TRANSAXLE FILL PLUG
2 - END COVER
21a - 52 T850 MANUAL TRANSAXLERG
DIFFERENTIAL (Continued)

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 Mopart
ATF+4 (Automatic Transmission FluidÐType 9602).
Use of substitute fluids may result in improper
transaxle operation and/or failure.
FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 135) and
drain fluid into suitable container.
(3) Install drain plug and torque to 14 N´m (120
in. lbs.).
FLUID FILL
(1) Remove transaxle fill plug (Fig. 136).
(2) Add 2.4-2.7L (2.5-2.9 qts.) of MopartATF+4
(Automatic Transmission FluidÐType 9602) until
fluid is within 1/8º 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 ò-turn clockwise (Fig. 137).(2) Remove gearshift boot from center console by
disengaging three (3) retaining clips (Fig. 138).
INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 138).
(2) Install gearshift knob (Fig. 137). Orient shift
pattern ò-turn clockwise, press down, and rotate
ò-turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
Fig. 135 Transaxle Drain Plug
1 - TRANSAXLE DRAIN PLUG
2 - DIFFERENTIAL COVER
Fig. 136 Transaxle Fill Plug
1 - TRANSAXLE FILL PLUG
2 - END COVER
Fig. 137 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-53
FLUID (Continued)

INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 236) is part
of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated pinion gear, and consists of the following com-
ponents:
²Intermediate Mainshaft
²1st Speed Gear
²2nd Speed Gear
²3/4 Cluster Gear
²5th Speed Gear
²Reverse Gear
²1/2 Synchronizer
²5/R Synchronizer
The intermediate shaft is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.DISASSEMBLY
CAUTION: Do not re-use snap rings when servicing
the intermediate shaft assembly. Discard upon dis-
assembly and install new ones provided with avail-
able snap ring service kit.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear.
(2) Install 8486-4 button to intermediate shaft.
Using arbor press ram, press reverse gear and inter-
mediate roller bearing off of shaft, while holding
remaining assembly with hand (Fig. 237).
Fig. 236 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
RGT850 MANUAL TRANSAXLE21a-81

TEST ACTION APPLICABILITY
7 Turn the ignition off.
At the Cooler In port, installa0to2070 KPa (300 PSI) gauge using a T.
Ensure the gauge hose is long enough to reach in the driver's side of the vehicle so the
gauge can be monitor while driving.
Road test the vehicle.
Transmission in the Driver gear.
Monitoring the DRB, achieve 80 km/h (50 mph).
NOTE: The gauge will read around 103 KPa (15 PSI) until lockup is achieved
in 3rd gear. If the TCC Solenoid operation is correct, the gauge pressure will
jump when the lockup is achieved.
Did the gauge pressure jump?All
Ye s®Go To 8
No®Refer to Service Manual for proper service procedure on Torque
Converter Assembly or Stuck TCC Solenoid and repair as neces-
sary.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
8 Turn the ignition off.
At the Cooler In port, installa0to2070 KPa (300 PSI) gauge using a T.
Ensure the gauge hose is long enough to reach in the driver's side of the vehicle so the
gauge can be monitor while driving.
Road test the vehicle.
Transmission in the Driver gear.
Monitoring the DRB, achieve 80 km/h (50 mph).
NOTE: The gauge will read around 103 KPa (15 PSI) until lockup is achieved
in 3rd gear. If the TCC Solenoid operation is properly, the gauge pressure
will jump when the lockup is achieved.
Maintain 80 km/h (50 MPH) per DRB. Wait 10 seconds in lockup. Record engine
RPM.
Was engine RPM 2200 RPM +/- 50 RPM?All
Ye s®Test Complete.
No®The problem appears to be in the Differential, Output Shaft or
Gear Box. Refer to Service Manual for proper service.
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
9WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform 31TH TRANSMISSION VERIFICATION TEST - VER
1..
No®Test Complete.
167
DRIVEABILITY - GAS
P0740-TORQ CONV CLU, NO RPM DROP AT LOCKUP (3SP AUTO TRANS)
Ð
Continued