2002 CHRYSLER CARAVAN shaft

(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, press intermediate shaft
out of 3/4 cluster gear (Fig. 237).
(12) Remove intermediate shaft from fixture and
remove 3/4 cluster gear from shaft (Fig. 238).
Fig. 235 Fixture 8483
1 - FIXTURE 8483
2 - COLLAR 8483-3
Fig. 236 Loading Intermediate Shaft
1 - FIXTURE 8483
1 - 3/4 CLUSTER GEAR
2 - COLLAR 8483-2
Fig. 237 Press Intermediate Shaft Out of 3/4 Cluster
Gear
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - 3/4 CLUSTER GEAR
4 - FIXTURE 8483
Fig. 238 3/4 Cluster Gear
1 - 3/4 CLUSTER GEAR
2 - INTERMEDIATE SHAFT
21 - 390 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(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 Gear Removal
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
Fig. 240 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 241 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 242 2nd Gear Outer Blocker Ring
1 - 2ND GEAR BLOCKER RING
RST850 MANUAL TRANSAXLE21 - 391
INTERMEDIATE SHAFT (Continued)
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(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 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 244 1/2 Synchronizer
1 - 1/2 SYNCHRONIZER
Fig. 245 1st Gear Blocker Ring
1 - 1ST GEAR BLOCKER RING
Fig. 246 1st Gear Friction Cone
1 - 1ST GEAR FRICTION CONE
21 - 392 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(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. 250).
Fig. 247 1st Gear Reactor Ring
1 - 1ST GEAR REACTOR RING
Fig. 248 1st Gear Removal
1 - 1ST GEAR
Fig. 249 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 250 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
RST850 MANUAL TRANSAXLE21 - 393
INTERMEDIATE SHAFT (Continued)
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(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 re-assembly.
Fig. 251 Intermediate Shaft Roller Bearing Removal
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - ROLLER BEARING
4 - BEARING SPLITTER P-334
21 - 394 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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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 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 252) for intermediate shaft
assembly reference.
(1) Press intermediate shaft into NEW roller bear-
ing with arbor press (Fig. 253).
Fig. 252 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
Fig. 253 Intermediate Shaft Bearing Installation
1 - ARBOR PRESS
2 - INTERMEDIATE SHAFT
3 - CAGED ROLLER BEARING
4 - BEARING SPLITTER
RST850 MANUAL TRANSAXLE21 - 395
INTERMEDIATE SHAFT (Continued)
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(2) Install intermediate shaft roller bearing snap
ring (Fig. 254).
(3) Install 1st gear roller bearing to intermediate
shaft (Fig. 255).(4) Install 1st gear to intermediate shaft (Fig.
256).
(5) Install 1/2 synchro to fixture 8483. Insert 1st
gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 257).
Fig. 254 Intermediate Shaft Roller Bearing Snap
Ring
1 - SNAP RING
Fig. 255 1st Gear Needle Bearing
1 - 1ST GEAR NEEDLE BEARING
Fig. 256 1st Gear Installation
1 - 1ST GEAR
Fig. 257 1/2 Synchro on Fixture 8483
1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER
21 - 396 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(6) Install intermediate shaft to synchro assembly
on fixture (Fig. 258).When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal.Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture.
(7) InstallNEW1/2 synchro snap ring (Fig. 259).
(8) Install 2nd gear blocker ring (Fig. 260).
Fig. 258 Install 1/2 Synchro to Intermediate Shaft
1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483
Fig. 259 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 260 2nd Gear Blocker Ring
1 - 2ND GEAR BLOCKER RING
RST850 MANUAL TRANSAXLE21 - 397
INTERMEDIATE SHAFT (Continued)
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