2002 CHRYSLER CARAVAN lock

(14) Install gearshift boot to console (Fig. 182).
Secure with three (3) retainer clips.
(15) Install gearshift knob to gearshift lever (Fig.
183). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(16) Connect battery negative cable.
GEARSHIFT KNOB
REMOVAL
(1) Separate gearshift boot from base of knob.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clockwise (Fig. 184).
INSTALLATION
(1) Install gearshift knob pattern1¤4-turn clock-
wise, press down, and rotate1¤4-turn counter clock-
wise (Fig. 184).
(2) Secure gearshift boot to base of knob.
Fig. 182 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 183 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 184 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21 - 374 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4turn clock-wise (Fig. 185).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 186).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
187).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
188).
Fig. 185 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 186 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 187 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 188 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
RST850 MANUAL TRANSAXLE21 - 375
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(6) Install center console assembly (Fig. 201).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(7) Install cupholder plugs (Fig. 202).(8) Install gearshift boot to console (Fig. 203).
Secure with three (3) retainer clips.
(9) Install gearshift knob to gearshift lever (Fig.
204). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 201 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 202 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 203 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 204 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RST850 MANUAL TRANSAXLE21 - 379
GEARSHIFT MECHANISM (Continued)
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(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) Remove 3rd gear blocker ring (Fig. 213).
Fig. 210 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 211 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 212 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 213 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
21 - 382 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)
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(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 synchronizer (Fig. 218).When
installing 3/4 synchronizer hub to shaft, make
sure to align oil slots on synchronizer hub face
with oil hole in the shaft splined hub journal.
(6) InstallNEW3/4 synchronizer snap ring (Fig.
219).
Fig. 216 3rd Gear Removal/Installation
1 - 3RD GEAR
Fig. 217 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 218 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 219 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
21 - 384 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)
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(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 200
N´m (148 ft. lbs.) using wrench 8478 (Fig. 223).
Fig. 220 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 221 4th Gear Removal/Installation
1 - 4th GEAR
Fig. 222 5th Gear Installation
1 - ARBOR PRESS RAM
2 - INSTALLER 8481
3 - 5TH GEAR
Fig. 223 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
RST850 MANUAL TRANSAXLE21 - 385
INPUT SHAFT (Continued)
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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) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear.
(2) Install 8486-4 button to intermediate shaft.
Using arbor press ram, press reverse gear and inter-
mediate roller bearing off of shaft, while holding
remaining assembly with hand (Fig. 228).
(3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 229).
(5) Remove 5/R synchro snap ring (Fig. 230).
Fig. 228 Bearing and Reverse Gear Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - SEALED ROLLER BEARING
4 - REVERSE GEAR
5 - BEARING SPLITTER P-334
Fig. 229 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 230 5/R Synchro Snap Ring
1 - SNAP RING
21 - 388 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(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 SYNCHRO ASSEMBLY
Fig. 232 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 233 5th Gear
1 - 5th GEAR
Fig. 234 3/4 Cluster Gear Snap Ring
1 - SNAP RING
RST850 MANUAL TRANSAXLE21 - 389
INTERMEDIATE SHAFT (Continued)
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