2002 CHRYSLER VOYAGER torque

(14) Install input shaft sealed roller bearing using
installer 8482 (Fig. 58).
(15) Installnewinput shaft bearing snap ring
(Fig. 59).(16) Install shift rail bushing to end cover using
installer 8475 (Fig. 60).
(17) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to transaxle end cover and install to
transaxle case (Fig. 61).While installing end
cover, be sure to guide oil trough into pocket
(Fig. 62).Torque end cover-to-case bolts to 28 N´m
(250 in. lbs.) (Fig. 63).
Fig. 58 Install Input Shaft Sealed Roller Bearing
1 - INSTALLER 8482
2 - SEALED ROLLER BEARING
Fig. 59 Input Shaft Bearing Snap Ring
1 - SNAP RING
Fig. 60 Shift Rail Bushing Installation
1 - INSTALLER 8475
Fig. 61 End Cover Removal/Installation
1 - END COVER
2 - OIL TROUGH
RST850 MANUAL TRANSAXLE21 - 333
T850 MANUAL TRANSAXLE (Continued)
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(18) Install lifting bar 8489 to geartrain.
(19) Lift up on bar (input shaft side) and install
input shaft bearing snap ring (Fig. 64).
(20) Lift up on bar (intermediate shaft side) and
install intermediate shaft bearing snap ring.
(21) Remove lifting bar 8489.
(22) Install a bead of MopartGear Lube RTV to
end plate and immediately install to case. Install and
torque bolts to 28 N´m (250 in. lbs.) (Fig. 65).
Fig. 62 Oil Trough Pocket
1 - OIL TROUGH
2 - POCKET
Fig. 63 End Cover Bolts
1 - BOLT (12)
Fig. 64 Input Bearing Snap Ring
1 - SNAP RING PLIERS
2 - LIFTING BAR 8489
3 - SNAP RING
Fig. 65 End Cover Bolts
1 - BOLT (11)
21 - 334 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(23) Install back up lamp switch and torque to 23
N´m (17 ft. lbs.) (Fig. 66).
(24) Roll transaxle assembly on side.
(25) Install differential chip collector magnet (Fig.
67). Retain to case with a dab of MopartGear Lube
RTV.
(26) Install differential assembly with bearing
races and select shim (Fig. 68). Shim selection was
determined before transaxle assembly (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS).
(27) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to differential cover and install to case.
Torque differential cover-to-case bolts to 54 N´m (40
ft. lbs.).
(28) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to extension housing. Install extensionhousing to differential cover and case and torque
bolts to 28 N´m (250 in. lbs.) (Fig. 69).
Fig. 66 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 67 Differential Magnet
1 - MAGNET
Fig. 68 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 69 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
RST850 MANUAL TRANSAXLE21 - 335
T850 MANUAL TRANSAXLE (Continued)
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(29) Install both axle output shaft seals using
driver handle C-4171 and installer 8473 (Fig. 70)
(Fig. 71).(30) Applya1mm(0.04 in.) bead of MopartGas-
ket Maker to shift cover assembly. Place shift cover
and transaxle geartrain into neutral and install shift
cover (Fig. 72) and torque bolts to 28 N´m (250 in.
lbs.).
(31) Install input shaft bearing retainer (Fig. 73).
Torque bolts to 12 N´m (105 in. lbs.).
Fig. 70 Axle Seal Installation (Extension Housing
Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
Fig. 71 Axle Seal InstallationÐTypical
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
Fig. 72 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
Fig. 73 Input Bearing Retainer
1 - INPUT BEARING RETAINER
21 - 336 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
(8) Install starter motor into position (Fig. 78).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(10) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 79). While
depressing inward, rotate slave cylinder clockwise
60tÉ into position until nylon locating tab rests
within transaxle case cutout, and hydraulic tube is
vertical. Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
Fig. 77 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 78 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 79 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
21 - 338 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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INSTALLATION - 2.5L TD
(1) Assemble transaxle to engine, while aligning
transaxle input shaft to clutch disc splines.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.) (Fig. 82).
(3) Install transaxle upper mount (Fig. 83). Install
and torque four (4) mount-to-transaxle bolts to 54
N´m (40 ft. lbs.).
(4) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(5) Remove screw jack.
(6) Connect back-up lamp switch connector.
Fig. 82 Transaxle Removal/Installation
1 - TRANSAXLE
2 - BOLT
Fig. 83 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
21 - 340 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

(7) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 85). Whiledepressing inward, rotate slave cylinder clockwise
60É into position until nylon locating tab rests within
transaxle case cutout, and hydraulic tube is vertical.
Connect ªquick-connectº connection until an audible
ªclickº is heard. Verify connection by pulling outward
on connection.
(10) Install underbody splash panel.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
86).
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 84 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 86 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RST850 MANUAL TRANSAXLE21 - 341
T850 MANUAL TRANSAXLE (Continued)
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INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear 0.66-1.84 mm (0.026-0.072 in.)
2nd Gear 0.66-1.84 mm (0.026-0.072 in.)
5th Gear 0.86-1.54 mm (0.034-0.061 in.)
Reverse 0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear 0.091-0.828 mm (0.004-0.033 in.)
2nd Gear 0.051-0.787 mm (0.002-0.031 in.)
5th Gear 0.102-0.762 mm (0.004-0.030 in.)
Reverse 0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION METRIC STANDARD
Differential Turning Torque 2.3-3.4 N´m 20-30 in. lbs.
Side Gear End Play (each side) 0.025-0.152 mm 0.001-0.006 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential Cover-to-Case 54 40 Ð
Bolt, End Cover-to-Case 28 Ð 250
Bolt, End Cover Plate-to-Cover 28 Ð 250
Bolt, Extension Housing-to-Case 28 Ð 250
Bolt, Reverse Idler Shaft-to-Case 54 40 Ð
Bolt, Ring Gear-to-Differential Case 95 70 Ð
Bolt, Shift Cover-to-Case 28 Ð 250
Nut, 5th Gear-to-Input Shaft 200 148 Ð
Plug, Drain 23 17 Ð
Screw, Input Bearing Retainer 12 Ð 105
Switch, Back-Up Lamp 23 17 Ð
Vent 7 Ð 60
21 - 344 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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