Page 1889 of 2321
(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)
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(9) Install 2nd gear friction cone (Fig. 270).
(10) Install 2nd gear reactor ring (Fig. 271).
(11) Install 2nd gear to intermediate shaft (Fig.
272).
(12) Press 3/4 cluster gear onto intermediate shaft
using cup 8481 (Fig. 273).
Fig. 270 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 271 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 272 2nd Gear
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
Fig. 273 Install 3/4 Cluster Gear using Tool 8481
1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR
RGT850 MANUAL TRANSAXLE21a-91
INTERMEDIATE SHAFT (Continued)
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(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)
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(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)
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(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)
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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
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(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)
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TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING..................1
TIRE AND WHEEL VIBRATION..............1
STANDARD PROCEDURE...................4
TIRE AND WHEEL BALANCE...............4
TIRE AND WHEEL MATCH MOUNTING.......6
TIRE AND WHEEL ROTATION..............6
REMOVAL...............................7
INSTALLATION............................7
TIRES
DESCRIPTION............................8
DIAGNOSIS AND TESTING..................9
TIRE NOISE............................9
TIRE/VEHICLE LEAD.....................9
TIRE WEAR PATTERNS..................11
TREAD WEAR INDICATORS...............11
STANDARD PROCEDURE..................11
TIRE INFLATION PRESSURES.............11
TIRE PRESSURE FOR HIGH SPEED
OPERATION...........................12TIRE LEAK REPAIRING..................12
CLEANING..............................13
WHEELS
DESCRIPTION...........................13
DIAGNOSIS AND TESTING.................13
WHEEL INSPECTION....................13
CLEANING..............................14
SPECIFICATIONS........................14
WHEEL COVER
DESCRIPTION...........................14
REMOVAL..............................14
INSTALLATION...........................14
WHEEL MOUNTING STUDS - FRONT
REMOVAL..............................15
INSTALLATION...........................16
WHEEL MOUNTING STUDS - REAR
REMOVAL..............................16
INSTALLATION...........................17
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
VIBRATION
Tire and wheel imbalance, runout and force varia-
tion can cause vehicles to exhibit steering wheel
vibration.
VISUAL INSPECTION
Visual inspection of the vehicle is recommended
prior to road testing or performing any other proce-
dure. Raise vehicle on a suitable hoist. Refer to
Hoisting in Lubrication and Maintenance.
Inspect for the following:
²Verify correct (OEM) wheel and tire, as well as
correct wheel weights. Aluminum wheels require
unique wheel weights. They are designed to fit the
contour of the wheel (Fig. 1).
²Inspect tires and wheels for damage, mud pack-
ing and unusual wear; correct as necessary.
²Check and adjust tire air pressure to the pres-
sure listed on the label attached to the rear face of
the driver's door.
ROAD TEST
Road test vehicle on a smooth road for a least five
miles to warm tires (remove any flat spots). Lightlyplace hands on steering wheel at the 10:00 and 2:00
positions while slowly sweeping up and down from 90
to 110 km/h (55 to 70 mph) where legal speed limits
allow.
Observe the steering wheel for:
²Visual Nibble (oscillation: clockwise/counter-
clockwise, usually due to tire imbalance)
Fig. 1 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
RSTIRES/WHEELS22-1
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