2001 CHRYSLER VOYAGER lock

(18) Remove 1/2 synchro from shaft (Fig. 253).
(19) Remove 1st gear blocker ring (Fig. 254).(20) Remove 1st gear friction cone (Fig. 255).
(21) Remove 1st gear reactor ring (Fig. 256).
Fig. 253 1/2 Synchronizer
1 - 1/2 SYNCHRONIZER
Fig. 254 1st Gear Blocker Ring
1 - 1ST GEAR BLOCKER RING
Fig. 255 1st Gear Friction Cone
1 - 1ST GEAR FRICTION CONE
Fig. 256 1st Gear Reactor Ring
1 - 1ST GEAR REACTOR RING
21a - 86 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 262).
(2) Install intermediate shaft roller bearing snap
ring (Fig. 263).
(3) Install 1st gear roller bearing to intermediate
shaft (Fig. 264).(4) Install 1st gear to intermediate shaft (Fig.
265).
(5) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 266).
(6) Install intermediate shaft to synchro assembly
on fixture (Fig. 267).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. 262 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
Fig. 263 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 264 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 265 1st Gear Installation
1 - 1ST GEAR
RGT850 MANUAL TRANSAXLE21a-89
INTERMEDIATE SHAFT (Continued)

(7) InstallNEW1/2 synchro snap ring (Fig. 268).
(8) Install 2nd gear blocker ring (Fig. 269).
Fig. 266 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. 267 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 268 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 269 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
21a - 90 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(13) InstallNEW3/4 cluster gear snap ring (Fig.
274).
(14) Install 5th gear to intermediate shaft (Fig.
275).(15) Install 5th gear blocker ring to synchronizer
(Fig. 276).
(16) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 277).When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
Fig. 274 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 275 5th Gear Installation
1 - 5th GEAR
Fig. 276 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 277 Install 5/R Synchro and 5th Blocker Ring to
5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
21a - 92 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

(17) InstallNEW5/R synchro snap ring (Fig. 278).
(18) Install reverse gear blocker ring (Fig. 279).
(19) Install reverse gear needle bearing (Fig. 280).
(20) Install reverse gear to intermediate shaft.
(21) Install intermediate shaft sealed roller bear-
ing and thrust washer using installer 8482 (Fig. 281).
Fig. 278 5/R Synchro Snap Ring
1 - SNAP RING
Fig. 279 Reverse Gear Blocker Ring
1 - REVERSE BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 280 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 281 Sealed Roller Bearing Installatiion
1 - ARBOR PRESS
2 - REMOVER/INSTALLER 8482
3 - SEALED ROLLER BEARING
4 - THRUST WASHER
RGT850 MANUAL TRANSAXLE21a-93
INTERMEDIATE SHAFT (Continued)

(22) InstallNEWintermediate shaft sealed bear-
ing snap ring (Fig. 282).
SHIFT COVER
DESCRIPTION
The shift cover assembly (Fig. 283) (Fig. 284) is
operated by the gearshift crossover and selector
cables, and operates the shift fork/shaft system. It
consists of crossover and selector lever mechanisms,
transaxle vent, a main shift selector shaft, and the
5-R blockout mechanism. The shift cover is only ser-
viced as an assembly.
Fig. 282 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
Fig. 283 Shift Lever Identification
1 - SHIFT COVER ASSEMBLY
2 - VENT
3 - CROSSOVER LEVER
4 - SELECTOR LEVER
Fig. 284 Shift Cover Assembly Components
1 - SHAFT
2 - 5-R BLOCKOUT PIN/CAM
3 - SHIFT SELECTOR
4 - SHIFT BLOCKER
5 - SELECTOR LEVER/DETENT
21a - 94 T850 MANUAL TRANSAXLERG
INTERMEDIATE SHAFT (Continued)

SHIFT FORK AND SHAFT
DESCRIPTION
The T850 utilizes a unique shift fork and shaft
arrangement consisting of three shift forks and two
shafts as shown in (Fig. 285). This system is oper-
ated by the shift cover assembly, which combined
with a unique gearshift cable design, offers a higher
mechanical advantage over traditional shift systems.
This arrangement results in less friction and lower
shift cable loads for smoother, more positive opera-
tion. The shift fork assemblies are constructed of
brass, float about the shafts with the aid of needle
bearings, and are serviced only as fork/bearing
assemblies.
SYNCHRONIZER
DESCRIPTION
The T850 transaxle uses two styles of synchronizer
assemblies; a conventional single-cone style is used
for the 5th/Reverse and 3rd/4th applications (Fig.
286), and a dual-cone style for the 1st/2nd gear appli-
cation (Fig. 287).
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ASSEMBLY
(1) Position synchronizer hub onto work bench.
Hub is non-directional.
Fig. 285 Shift Fork/Shaft Components
1 - 5/R FORK
2 - SHAFT/LINK ASSEMBLY
3 - LINK
4 - 3/4 FORK
5 - 1/2 FORK
Fig. 286 3/4-5/R Synchronizer Assembly
1 - SLEEVE
2 - HUB
3 - BLOCKER RING (2)
4 - SPRING (3)
5 - KEY (3)
6 - BALL (3)
RGT850 MANUAL TRANSAXLE21a-95

(2) Install springs into hub slot.
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key.
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position.
VEHICLE SPEED SENSOR
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the speed sensor connector (Fig.
288).
CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.(3) Remove speed sensor retaining bolt (Fig. 288).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into trans-
axle. Should sensor drive gear fall into the trans-
axle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) Install pinion gear to speed sensor (Fig. 288) .
(2) Using a NEW o-ring, install the speed sensor
to the transaxle (Fig. 288) .
(3) Install the bolt and torque to 7 N´m (60 in.
lbs.).
(4) Connect speed sensor connector (Fig. 288) .
(5) Lower vehicle and road test to verify proper
speedometer operation.
Fig. 287 1/2 Synchronizer Assembly
1 - SLEEVE
2 - REACTOR RING (2)
3 - HUB
4 - BLOCKER RING (2)
5 - SLEEVE
6 - FRICTION CONE (2)
7 - SPRING (3)
8 - KEY (3)
9 - BALL (3)
Fig. 288 Speed Sensor and Pinion Removal/
InstallationÐTypical
1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - GEAR
21a - 96 T850 MANUAL TRANSAXLERG
SYNCHRONIZER (Continued)