2002 CHRYSLER VOYAGER Service Manual

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Page 1865 of 2399

CHRYSLER VOYAGER 2002 Service Manual T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION........................308
OPERATION..........................311
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES.....

T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION........................308
OPERATION..........................311
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES...................318
REMOVAL............................318
DISASSEMBLY........................323
ASSEMBLY...........................329
INSTALLATION........................338
SPECIFICATIONS - T850 MANUAL
TRANSAXLE........................343
SPECIAL TOOLS - T850 TRANSAXLE.......345
AXLE SEALS
REMOVAL............................348
INSTALLATION........................348
BACK-UP LAMP SWITCH
REMOVAL............................349
INSTALLATION........................349
DIFFERENTIAL
DESCRIPTION........................349
OPERATION..........................349
DISASSEMBLY........................350
ASSEMBLY...........................353
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE...........................356
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY..........................358
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................358
STANDARD PROCEDURE - FLUID DRAIN
AND FILL...........................359
GEARSHIFT BOOT
REMOVAL............................359
INSTALLATION........................360GEARSHIFT CABLE - CROSSOVER
REMOVAL............................360
INSTALLATION........................363
ADJUSTMENTS
ADJUSTMENT.......................366
GEARSHIFT CABLE - SELECTOR
REMOVAL............................368
INSTALLATION........................371
GEARSHIFT KNOB
REMOVAL............................374
INSTALLATION........................374
GEARSHIFT MECHANISM
REMOVAL............................375
INSTALLATION........................377
INPUT SHAFT
DESCRIPTION........................380
DISASSEMBLY........................380
ASSEMBLY...........................383
INTERMEDIATE SHAFT
DESCRIPTION........................387
DISASSEMBLY........................388
ASSEMBLY...........................395
SHIFT COVER
DESCRIPTION........................401
SHIFT FORK AND SHAFT
DESCRIPTION........................402
SYNCHRONIZER
DESCRIPTION........................402
DISASSEMBLY........................402
CLEANING
CLEAN............................402
INSPECTION
INSPECT...........................402
ASSEMBLY...........................403
VEHICLE SPEED SENSOR
REMOVAL............................403
INSTALLATION........................403
T850 MANUAL TRANSAXLE
DESCRIPTION
The NV T850 5-speed transaxle (Fig. 1) is a con-
stant-mesh manual transaxle that is synchronized in
all gear ranges, including reverse.
The transaxle consists of three major sub-assem-
blies: the input shaft, intermediate shaft, and differ-ential assembly. The transaxle shift system consists
of a mechanical shift cover, rails, forks, and cables.
The unique design of this shift system provides a
higher mechanical advantage, resulting in less fric-
tion and lower shift cable loads for smoother, more
positive operation.
21 - 308 T850 MANUAL TRANSAXLERS
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CHRYSLER VOYAGER 2002 Service Manual Fig. 1 NV T850 Transaxle
1 - 3RD GEAR (SPEED) 9 - INTERMEDIATE SHAFT BEARING
(SEALED BALL)17 - 1/2 SYNCHRONIZER
2 - 3/4 SYNCHRONIZER 10 - REVERSE GEAR 18 - 1ST GEAR (SPEED)
3 - 3/4 SHIFT FORK 11 - 5/R

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CHRYSLER VOYAGER 2002 Service Manual The NV T850 transaxle is available with the 2.4L
Gas and 2.5L Turbo Diesel engine options. Unique
gearing tailored to the performance characteristics of
each engine provides optimum driveability, grad

Page 1868 of 2399

CHRYSLER VOYAGER 2002 Service Manual OPERATION
NEUTRAL
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. Since
no synchronizers are engaged on either the input or
intermediate shafts, power

Page 1869 of 2399

CHRYSLER VOYAGER 2002 Service Manual 1ST GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft first gear is integral to the input shaft,
and is in constant mesh with the i

Page 1870 of 2399

CHRYSLER VOYAGER 2002 Service Manual 2ND GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft second gear is integral to the input shaft,
and is in constant mesh with the

Page 1871 of 2399

CHRYSLER VOYAGER 2002 Service Manual 3RD GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft third speed gear is in constant mesh with
the intermediate shaft 3-4 cluster

Page 1872 of 2399

CHRYSLER VOYAGER 2002 Service Manual 4TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fourth speed gear is in constant mesh
with the intermediate shaft 3-4 cluster

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