2002 CHRYSLER CARAVAN shaft

(5) Install shift forks and 3/4 rail assembly to
geartrain as shown in (Fig. 51).
NOTE: Before installing geartrain, make sure that
input shaft sealed roller bearing is not installed,
otherwise reverse idler assembly installation will be
difficult. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/INPUT SHAFT - DISASSEMBLY)
(6) Install lifting bar 8489 to geartrain. Install
geartrain to case.When installing geartrain to
case, use care not to damage bearing surfaces.
(7) Remove lifting bar 8489 from geartrain.
(8) Install shift 1/2-5/R rail as shown in (Fig. 52).
(9) Install reverse idler shaft into position (Fig.
53). Install and torque shaft-to-case bolt to 54 N´m
(40 ft. lbs.).
Fig. 51 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 52 Shift Rail Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 53 Install Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
2 - BOLT
RST850 MANUAL TRANSAXLE21 - 331
T850 MANUAL TRANSAXLE (Continued)
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(10) Install reverse idler gear bearing (Fig. 54).
(11) Install reverse idler gear with hub down as
shown in (Fig. 55).(12) Install flat washer (Fig. 56).
(13) Install wave washer (Fig. 57).
Fig. 54 Install Reverse Idler Gear Bearing
1 - NEEDLE BEARING
2 - REVERSE IDLER SHAFT
Fig. 55 Install Reverse Idler Gear
1 - REVERSE IDLER GEAR
Fig. 56 Install Flat Washer
1 - FLAT WASHER
Fig. 57 Install Wave Washer
1 - WAVE WASHER
21 - 332 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(14) Install input shaft sealed roller bearing using
installer 8482 (Fig. 58).
(15) Installnewinput shaft bearing snap ring
(Fig. 59).(16) Install shift rail bushing to end cover using
installer 8475 (Fig. 60).
(17) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to transaxle end cover and install to
transaxle case (Fig. 61).While installing end
cover, be sure to guide oil trough into pocket
(Fig. 62).Torque end cover-to-case bolts to 28 N´m
(250 in. lbs.) (Fig. 63).
Fig. 58 Install Input Shaft Sealed Roller Bearing
1 - INSTALLER 8482
2 - SEALED ROLLER BEARING
Fig. 59 Input Shaft Bearing Snap Ring
1 - SNAP RING
Fig. 60 Shift Rail Bushing Installation
1 - INSTALLER 8475
Fig. 61 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
RST850 MANUAL TRANSAXLE21 - 333
T850 MANUAL TRANSAXLE (Continued)
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(18) Install lifting bar 8489 to geartrain.
(19) Lift up on bar (input shaft side) and install
input shaft bearing snap ring (Fig. 64).
(20) Lift up on bar (intermediate shaft side) and
install intermediate shaft bearing snap ring.
(21) Remove lifting bar 8489.
(22) Install a bead of MopartGear Lube RTV to
end plate and immediately install to case. Install and
torque bolts to 28 N´m (250 in. lbs.) (Fig. 65).
Fig. 62 Oil Trough Pocket
1 - OIL TROUGH
2 - POCKET
Fig. 63 End Cover Bolts
1 - BOLT (12)
Fig. 64 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
Fig. 65 End Cover Bolts
1 - BOLT (11)
21 - 334 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(29) Install both axle output shaft seals using
driver handle C-4171 and installer 8473 (Fig. 70)
(Fig. 71).(30) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to shift cover assembly. Place shift cover
and transaxle geartrain into neutral and install shift
cover (Fig. 72) and torque bolts to 28 N´m (250 in.
lbs.).
(31) Install input shaft bearing retainer (Fig. 73).
Torque bolts to 12 N´m (105 in. lbs.).
Fig. 70 Axle Seal Installation (Extension Housing
Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
Fig. 71 Axle Seal InstallationÐTypical
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
Fig. 72 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 73 Input Bearing Retainer
1 - INPUT BEARING RETAINER
21 - 336 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
80).
(14) Connect gearshift cables to shift levers/cover
assembly (Fig. 81). Install cables into position at
mount bracket and secure with retaining clips.
(15) Connect battery cables.
(16) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
Fig. 80 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 81 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21 - 339
T850 MANUAL TRANSAXLE (Continued)
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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).
(3) Install transaxle upper mount (Fig. 83). 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.
Fig. 82 Transaxle Removal/Installation
1 - TRANSAXLE
2 - BOLT
Fig. 83 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
21 - 340 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(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 (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) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 85). Whiledepressing inward, rotate slave cylinder 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.
(10) Install underbody splash panel.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
86).
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 86 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RST850 MANUAL TRANSAXLE21 - 341
T850 MANUAL TRANSAXLE (Continued)
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