2002 CHRYSLER CARAVAN Service Manual

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Page 1945 of 2399

CHRYSLER CARAVAN 2002 Service Manual DISASSEMBLY CAUTION: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard upon dis- assembly and install new ones provided with avail- able snap ring service kit. (1) Insta

Page 1946 of 2399

CHRYSLER CARAVAN 2002 Service Manual (6) Remove 5/R synchro (Fig. 231). (7) Remove 5th gear blocker ring (Fig. 232).(8) Remove 5th gear (Fig. 233). (9) Remove 3/4 cluster gear snap ring (Fig. 234). Fig. 231 5/R Synchronizer 1 - 5/R SYNCH

Page 1947 of 2399

CHRYSLER CARAVAN 2002 Service Manual (10) Install shaft assembly into fixture 8483, with split collar 8483-3 oriented chamfer side up (Fig. 235). Place 8483-2 into position with chamfer side up (Fig. 236). (11) Using an arbor press, pres

Page 1948 of 2399

CHRYSLER CARAVAN 2002 Service Manual (13) Remove 2nd gear from shaft (Fig. 239). (14) Remove 2nd gear reactor ring (Fig. 240).(15) Remove 2nd gear friction cone (Fig. 241). (16) Remove 2nd Gear outer blocker ring (Fig. 242). Fig. 239 2nd

Page 1949 of 2399

CHRYSLER CARAVAN 2002 Service Manual (17) Remove 1/2 synchro snap ring (Fig. 243). (18) Remove 1/2 synchro from shaft (Fig. 244).(19) Remove 1st gear blocker ring (Fig. 245). (20) Remove 1st gear friction cone (Fig. 246). Fig. 243 1/2 Sy

Page 1950 of 2399

CHRYSLER CARAVAN 2002 Service Manual (21) Remove 1st gear reactor ring (Fig. 247). (22) Remove 1st gear from shaft (Fig. 248).(23) Remove 1st gear needle bearing (Fig. 249). (24) Remove intermediate shaft roller bearing snap ring (Fig. 2

Page 1951 of 2399

CHRYSLER CARAVAN 2002 Service Manual (25) Press intermediate shaft out of roller bearing supported by bearing splitter P-334 (Fig. 251). Roller bearing is not re-usable once removed. It is necessary to install a new roller bearing upon r

Page 1952 of 2399

CHRYSLER CARAVAN 2002 Service Manual ASSEMBLY NOTE: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard snap rings and install new ones provided with available snap ring service kit. NOTE: When installing 1/2
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