2002 CHRYSLER VOYAGER clutch

(6) Install thermal valve into transfer plate (Fig.
373).
(7) Install separator plate to valve body (Fig. 374).(8) Install the overdrive clutch (#5) check valve to
separator plate (Fig. 375)
(9) Install oil screen to separator plate (Fig. 376).
Fig. 373 Install Thermal Valve
1 - THERMAL VALVE
Fig. 374 Install Separator Plate
1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 375 Install Overdrive Clutch (#5) Check Valve
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
Fig. 376 Install Oil Screen
1 - OIL SCREEN
21 - 304 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)
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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 is not transmitted to the
intermediate shaft and the differential does not turn
(Fig. 3).
Fig. 3 Neutral Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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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 intermediate shaft
first speed gear. Because of this constant mesh, the
intermediate shaft first speed gear freewheels until
first gear is selected. As the gearshift lever is moved
to the first gear position, the 1-2 fork moves the 1-2
synchronizer sleeve towards first gear on the inter-
mediate shaft. The synchronizer sleeve engages the
first gear clutch teeth, fixing the gear to the interme-
diate shaft, and allowing power to transmit through
the intermediate shaft to the differential (Fig. 4).
Fig. 4 1st Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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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 intermediate shaft
second speed gear. Because of this constant mesh,
the intermediate shaft second speed gear freewheels
until second gear is selected. As the gearshift lever is
moved to the second gear position, the 1-2 fork moves
the 1-2 synchronizer sleeve towards second gear on
the intermediate shaft. The synchronizer sleeve
engages the second gear clutch teeth, fixing the gear
to the intermediate shaft, and allowing power to
transmit through the intermediate shaft to the differ-
ential (Fig. 5).
Fig. 5 2nd Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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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 gear, which is fixed
to the intermediate shaft. Because of this constant
mesh, the input shaft third speed gear freewheels
until third gear is selected. As the gearshift lever is
moved to the third gear position, the 3-4 fork moves
the 3-4 synchronizer sleeve towards third gear on the
input shaft. The synchronizer sleeve engages the
third gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 6).
Fig. 6 3rd Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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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 gear, which is
fixed to the intermediate shaft. Because of this con-
stant mesh, the input shaft fourth speed gear free-
wheels until fourth gear is selected. As the gearshift
lever is moved to the fourth gear position, the 3-4
fork moves the 3-4 synchronizer sleeve towards
fourth gear on the input shaft. The synchronizer
sleeve engages the fourth gear clutch teeth, fixing
the gear to the input shaft, and allowing power to
transmit through the intermediate shaft to the differ-
ential (Fig. 7).
Fig. 7 4th Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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5TH GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft fifth gear is pressed on to the input shaft,
and is in constant mesh with the intermediate shaft
fifth speed gear. Because of this constant mesh, the
intermediate shaft fifth speed gear freewheels until
fifth gear is selected. As the gearshift lever is moved
to the fifth gear position, the 5-R fork moves the 5-R
synchronizer sleeve towards the intermediate shaft
fifth speed gear. The synchronizer sleeve engages the
fifth gear clutch teeth, fixing the gear to the input
shaft, and allowing power to transmit through the
intermediate shaft to the differential (Fig. 8).
Fig. 8 5th Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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REVERSE GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft reverse gear is integral to the input
shaft, and is in constant mesh with the reverse idler
gear. The reverse idler gear, which reverses the rota-
tion of the intermediate shaft, is in constant mesh
with the intermediate shaft reverse gear. Because of
this constant mesh, the intermediate shaft reverse
gear freewheels until reverse gear is selected. As the
gearshift lever is moved to the reverse gear position,
the 5-R fork moves the 5-R synchronizer sleeve
towards the intermediate shaft reverse gear. The
synchronizer sleeve engages the reverse gear clutch
teeth, fixing the gear to the intermediate shaft, and
allowing power to transmit through the intermediate
shaft to the differential (in reverse) (Fig. 9).
Fig. 9 Reverse Gear Operation
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T850 MANUAL TRANSAXLE (Continued)
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