2001 DODGE TOWN AND COUNTRY Engine

(14) Disconnect back-up lamp switch connector.
(15) Remove structural collar.
(16) Remove modular clutch assembly-to-drive
plate bolts.
(17) Position screw jack and wood block to engine
oil pan.
(18) Remove transmission upper mount through-
bolt from left frame rail.
(19) Lower engine/transaxle assembly on screw
jack.
(20) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 15).
(21) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(22) Remove transaxle from engine.
(23) Inspect modular clutch assembly, clutch
release components, and engine drive plate.
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 13 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 12 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(5) Remove battery tray (Fig. 18). Disconnect bat-
tery temperature sensor.
(6) Remove coolant recovery bottle from bracket.
(7) Remove coolant recovery bottle mounting
bracket (Fig. 19).
(8) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 20).
(9) Remove gearshift cable retaining clips from
mounting bracket (Fig. 20). Remove cables and
secure out of way.(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 21).
Fig. 18 Battery Tray
1 - BATTERY TRAY
Fig. 19 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 20 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 21 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
21a - 14 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove cradle plate.
(16) Remove front harness retainer and secure
harness out of way.
(17) Remove clutch release access cover.
(18)RHD Models:Using Tool 6638A, disconnect
clutch hydraulic circuit quick connect (located on
slave cylinder tube). Remove clutch slave cylinder by
depressing towards case and rotating counter-clock-
wise 60É, while lifting anti-rotation tab out of case
slot with screwdriver (Fig. 22).LHD Models:
Remove clutch release cable by pulling outward on
cable housing, then forward to allow cable core to
pass through case slot (Fig. 23). Disengage T-end
from release lever and secure cable out of way.
(19) Remove engine left mount bracket (Fig. 24).
(20) Remove starter motor (Fig. 25).
(21) Disconnect back-up lamp switch connector.
(22) Position screw jack and wood block to engine
oil pan.
(23) Remove transmission upper mount through-
bolt from left frame rail.
(24) Lower engine/transaxle assembly on screw
jack.(25) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 26).
(26) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(27) Remove transaxle from engine (Fig. 27).
(28) Inspect clutch, clutch release components, and
flywheel.
Fig. 22 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 23 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 24 Left Mount Bracket Removal/Installation
1 - BOLT (2)
2 - MOUNT BRACKET
3 - BOLT (2)
RGT850 MANUAL TRANSAXLE21a-15
T850 MANUAL TRANSAXLE (Continued)
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INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
Fig. 80 Pivot Ball Position (RHD)
1 - PIVOT BALL (1)
Fig. 81 Release Bearing-to-Lever (LHD ShownÐRHD
Typical)
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 82 Release Bearing and Lever (LHD)
1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 83 Release Bearing and Lever (RHD)
1 - RELEASE LEVER
2 - RELEASE BEARING
RGT850 MANUAL TRANSAXLE21a-31
T850 MANUAL TRANSAXLE (Continued)
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(8) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(10)RHD Models:Install clutch slave cylinder
into position, noting orientation of different sized
lugs (Fig. 85). While depressing inward, rotate slave
cylinder clockwise 60tÉ into position until nylon
locating tab rests within transaxle case cutout, and
hydraulic tube is vertical. Connect ªquick-connectº
connection until an audible ªclickº is heard. Verify
connection by pulling outward on connection.LHD
Models:Insert T-end of clutch release cable into
clutch release lever provision. Route cable through
transaxle case cutout, and seat cable housing with
grommet to transaxle case (Fig. 86).
(11) Install clutch access hole cover.
(12) Install cradle plate.
(13) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(14) Lower vehicle.
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 86 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
21a - 32 T850 MANUAL TRANSAXLERG
T850 MANUAL TRANSAXLE (Continued)
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(15) Install right mount bracket to transaxle (Fig.
87).
(16) Connect gearshift cables to shift levers/cover
assembly (Fig. 88). Install cables into position at
mount bracket and secure with retaining clips.
(17) Connect battery cables.
(18) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
INSTALLATION - 2.5L TD
(1) Assemble transaxle to engine, while aligning
transaxle input shaft to clutch disc splines.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.) (Fig. 89).
(3) Install transaxle upper mount (Fig. 90). Install
and torque four (4) mount-to-transaxle bolts to 54
N´m (40 ft. lbs.).
(4) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(5) Remove screw jack.
(6) Connect back-up lamp switch connector.
(7) Install starter motor into position (Fig. 91).
Install and torque bolts to 54 N´m (40 ft. lbs.).Fig. 87 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 88 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RGT850 MANUAL TRANSAXLE21a-33
T850 MANUAL TRANSAXLE (Continued)
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(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9)RHD Models:Install clutch slave cylinder into
position, noting orientation of different sized lugs
(Fig. 92). While depressing inward, rotate slave cyl-
inder clockwise 60É into position until nylon locating
tab rests within transaxle case cutout, and hydraulic
tube is vertical. Connect ªquick-connectº connection
until an audible ªclickº is heard. Verify connection by
pulling outward on connection.LHD Models:Insert
T-end of clutch release cable into clutch release lever
provision. Route cable through transaxle case cutout,
and seat cable housing with grommet to transaxle
case (Fig. 93).
(10) Install clutch access hole cover.
(11) Install cradle plate.
(12) Install underbody splash panel.
(13) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(14) Lower vehicle.
(15) Install right mount bracket to transaxle (Fig.
94).
Fig. 92 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 93 Clutch Release Cable at Transaxle
1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 94 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RGT850 MANUAL TRANSAXLE21a-35
T850 MANUAL TRANSAXLE (Continued)
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(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)
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