2002 CHRYSLER CARAVAN Service Manual

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Page 1897 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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. 82

Page 1898 of 2399

CHRYSLER CARAVAN 2002 Service Manual (7) Install starter motor into position (Fig. 84). Install and torque bolts to 54 N´m (40 ft. lbs.). (8) Install engine front mount bracket. Install and torque bracket-to-transaxle bolts to 102 N´m

Page 1899 of 2399

CHRYSLER CARAVAN 2002 Service Manual (14) Connect gearshift cables to shift levers/cover assembly (Fig. 87). Install cables into position at mount bracket and secure with retaining clips. (15) Install coolant recovery bottle bracket (Fig

Page 1900 of 2399

CHRYSLER CARAVAN 2002 Service Manual (19) Install battery thermal shield and clutch cable eyelet (Fig. 91).(20) Connect battery cables. (21) Check transaxle fluid and engine coolant lev- els. Adjust if necessary. (Refer to 21 - TRANSMIS-

Page 1901 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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

Page 1902 of 2399

CHRYSLER CARAVAN 2002 Service Manual SPECIAL TOOLS - T850 TRANSAXLE Bearing Splitter, P-334 Slide Hammer, C-3752 Universal Handle, C-4171 Torque Tool, C-4995 Puller Set, 5048 Disconnect Tool, 6638A Remover, 6786 RST850 MANUAL TRANSAXLE21

Page 1903 of 2399

CHRYSLER CARAVAN 2002 Service Manual Remover/Installer, 6891 Alignment Pins, 8470 Installer, 8471 Race Remover, 8472 Bearing Installer, 8473 Remover/Installer, 8474 Installer, 8475 Installer, 8476 Wrench, 8478 21 - 346 T850 MANUAL TRANSA

Page 1904 of 2399

CHRYSLER CARAVAN 2002 Service Manual Stake Tool, 8479 Installer, 8481 Bearing Installer, 8482 Fixture, 8483 Fixture, 8487 Lifting Bar, 8489 Thrust Buttons, 8491 Wrench, 8827 RST850 MANUAL TRANSAXLE21 - 347 T850 MANUAL TRANSAXLE (Continue
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