2002 CHRYSLER CARAVAN Service Manual

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Page 1937 of 2399

CHRYSLER CARAVAN 2002 Service Manual INPUT SHAFT DESCRIPTION The input shaft assembly (Fig. 205) is part of the transaxle geartrain, is driven by the clutch assembly, and consists of the following components: ²Input Mainshaft ²3rd Spee

Page 1938 of 2399

CHRYSLER CARAVAN 2002 Service Manual (3) Remove input bearing. Place input shaft assembly onto arbor press table, with the input bear- ing supported by bearing splitter (Fig. 207). Using adapter 8486-4, press bearing off of shaft, while

Page 1939 of 2399

CHRYSLER CARAVAN 2002 Service Manual (8) Remove 4th gear blocker ring (Fig. 210). (9) Remove 3/4 synchronizer snap ring (Fig. 211). Discard and replace with new snap ring upon assem- bly.(10) Remove 3/4 synchronizer (Fig. 212). (11) Remo

Page 1940 of 2399

CHRYSLER CARAVAN 2002 Service Manual (12) Remove 3rd gear (Fig. 214). (13) Inspect third gear thrust washer for signs of excessive wear. To replace, drive off of input shaft with suitable drift and hammer. ASSEMBLY NOTE: When servicing t

Page 1941 of 2399

CHRYSLER CARAVAN 2002 Service Manual (1) Install input shaft into fixture 8487. (2) Install thrust washer if removed upon disas- sembly. (3) Install 3rd gear (Fig. 216). (4) Install 3rd gear blocker ring (Fig. 217).(5) Install 3/4 synchr

Page 1942 of 2399

CHRYSLER CARAVAN 2002 Service Manual (7) Install 4th gear blocker ring (Fig. 220). (8) Install 4th gear (Fig. 221). (9) Install 5th gear and press into position using installer 8481 (Fig. 222). (10) InstallNEW5th gear nut and torque to 2

Page 1943 of 2399

CHRYSLER CARAVAN 2002 Service Manual (11) Stake 5th Gear nut as follows: (a) Install staking tool 8479 to 5th gear nut. (b) Tighten upper thumb screw by hand (Fig. 224). (c) Tighten two (2) side thumb screws by hand. (d) Tighten both sta

Page 1944 of 2399

CHRYSLER CARAVAN 2002 Service Manual INTERMEDIATE SHAFT DESCRIPTION The intermediate shaft assembly (Fig. 227) is part of the transaxle geartrain, meshes with and is driven by the input shaft, drives the differential via an inte- grated
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