2002 CHRYSLER CARAVAN lock

(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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(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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(13) InstallNEW3/4 cluster gear snap ring (Fig.
265).
(14) Install 5th gear to intermediate shaft (Fig.
266).(15) Install 5th gear blocker ring to synchronizer
(Fig. 267).
(16) Install 5th gear synchronizer assembly to
intermediate shaft (Fig. 268).When installing 5/R
synchronizer, make sure to align oil slots on
synchronizer hub face with oil hole in the shaft
splined hub journal.
Fig. 265 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 266 5th Gear Installation
1 - 5th GEAR
Fig. 267 5th Gear Blocker Ring to Synchro
1 - 5th GEAR BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 268 Install 5/R Synchro and 5th Blocker Ring to
5th Gear
1 - 5/R SYNCHRONIZER
2 - 5TH GEAR BLOCKER RING
3 - 5TH GEAR
RST850 MANUAL TRANSAXLE21 - 399
INTERMEDIATE SHAFT (Continued)
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(17) InstallNEW5/R synchro snap ring (Fig. 269).
(18) Install reverse gear blocker ring (Fig. 270).
(19) Install reverse gear needle bearing (Fig. 271).
(20) Install reverse gear to intermediate shaft.
(21) Install intermediate shaft sealed roller bear-
ing and thrust washer using installer 8482 (Fig. 272).
Fig. 269 5/R Synchro Snap Ring
1 - SNAP RING
Fig. 270 Reverse Gear Blocker Ring
1 - REVERSE BLOCKER RING
2 - 5/R SYNCHRONIZER
Fig. 271 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 272 Sealed Roller Bearing Installatiion
1 - ARBOR PRESS
2 - REMOVER/INSTALLER 8482
3 - SEALED ROLLER BEARING
4 - THRUST WASHER
21 - 400 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
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(22) InstallNEWintermediate shaft sealed bear-
ing snap ring (Fig. 273).
SHIFT COVER
DESCRIPTION
The shift cover assembly (Fig. 274) (Fig. 275) is
operated by the gearshift crossover and selector
cables, and operates the shift fork/shaft system. It
consists of crossover and selector lever mechanisms,
transaxle vent, a main shift selector shaft, and the
5-R blockout mechanism. The shift cover is only ser-
viced as an assembly.
Fig. 274 Shift Lever Identification
1 - SHIFT COVER ASSEMBLY
2 - VENT
3 - CROSSOVER LEVER
4 - SELECTOR LEVER
Fig. 273 Intermediate Shaft Bearing Snap Ring
1 - SNAP RING
2 - BEARING
Fig. 275 Shift Cover Assembly Components
1 - SHAFT
2 - 5-R BLOCKOUT PIN/CAM
3 - SHIFT SELECTOR
4 - SHIFT BLOCKER
5 - SELECTOR LEVER/DETENT
RST850 MANUAL TRANSAXLE21 - 401
INTERMEDIATE SHAFT (Continued)
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SHIFT FORK AND SHAFT
DESCRIPTION
The T850 utilizes a unique shift fork and shaft
arrangement consisting of three shift forks and two
shafts as shown in (Fig. 276). This system is oper-
ated by the shift cover assembly, which combined
with a unique gearshift cable design, offers a higher
mechanical advantage over traditional shift systems.
This arrangement results in less friction and lower
shift cable loads for smoother, more positive opera-
tion. The shift fork assemblies are constructed of
brass, float about the shafts with the aid of needle
bearings, and are serviced only as fork/bearing
assemblies.
SYNCHRONIZER
DESCRIPTION
The T850 transaxle uses two styles of synchronizer
assemblies; a conventional single-cone style is used
for the 5th/Reverse and 3rd/4th applications (Fig.
277), and a dual-cone style for the 1st/2nd gear appli-
cation (Fig. 278).
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
CLEANING
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECTION
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
Fig. 276 Shift Fork/Shaft Components
1 - 5/R FORK
2 - SHAFT/LINK ASSEMBLY
3 - LINK
4 - 3/4 FORK
5 - 1/2 FORK
Fig. 277 3/4-5/R Synchronizer Assembly
1 - SLEEVE
2 - HUB
3 - BLOCKER RING (2)
4 - SPRING (3)
5 - KEY (3)
6 - BALL (3)
21 - 402 T850 MANUAL TRANSAXLERS
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