2003 CHRYSLER CARAVAN Service Manual

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Page 1465 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.
(1) Clean and inspect seal area.
(2)

Page 1466 of 2177

CHRYSLER CARAVAN 2003 Service Manual OUTER HALF SHAFT SEAL
REMOVAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Lift vehicle on hoist.
(2) Remove r

Page 1467 of 2177

CHRYSLER CARAVAN 2003 Service Manual (3) Index rear cover to the case for later reassem-
bly (Fig. 51).
(4) Pull rear cover out of the P.T.U. case (Fig. 52).
(5) Remove rear cover O-Ring (Fig. 53).
INSTALLATION
(1) To install, reverse re

Page 1468 of 2177

CHRYSLER CARAVAN 2003 Service Manual T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION.........................21
OPERATION...........................24
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES.....

T850 MANUAL TRANSAXLE
TABLE OF CONTENTS
page page
T850 MANUAL TRANSAXLE
DESCRIPTION.........................21
OPERATION...........................24
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES....................30
REMOVAL.............................31
DISASSEMBLY.........................35
ASSEMBLY............................42
INSTALLATION.........................51
SPECIFICATIONS - T850 MANUAL
TRANSAXLE.........................56
SPECIAL TOOLS - T850 TRANSAXLE........58
AXLE SEALS
REMOVAL.............................61
INSTALLATION.........................61
BACK-UP LAMP SWITCH
REMOVAL.............................62
INSTALLATION.........................62
DIFFERENTIAL
DESCRIPTION.........................62
OPERATION...........................62
DISASSEMBLY.........................62
ASSEMBLY............................66
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL TURNING
TORQUE............................69
ADJUSTMENT - DIFFERENTIAL SIDE GEAR
ENDPLAY...........................70
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK.............................71
STANDARD PROCEDURE - FLUID DRAIN
AND FILL............................71
GEARSHIFT BOOT
REMOVAL.............................72
INSTALLATION.........................73GEARSHIFT CABLE - CROSSOVER
REMOVAL.............................73
INSTALLATION.........................76
ADJUSTMENTS
ADJUSTMENT........................79
GEARSHIFT CABLE - SELECTOR
REMOVAL.............................81
INSTALLATION.........................84
GEARSHIFT KNOB
REMOVAL.............................87
INSTALLATION.........................87
GEARSHIFT MECHANISM
REMOVAL.............................87
INSTALLATION.........................89
INPUT SHAFT
DESCRIPTION.........................93
DISASSEMBLY.........................93
ASSEMBLY............................96
INTERMEDIATE SHAFT
DESCRIPTION........................100
DISASSEMBLY........................100
ASSEMBLY...........................107
SHIFT COVER
DESCRIPTION........................113
SHIFT FORK AND SHAFT
DESCRIPTION........................113
SYNCHRONIZER
DESCRIPTION........................114
DISASSEMBLY........................114
CLEANING
CLEAN.............................114
INSPECTION
INSPECT...........................114
ASSEMBLY...........................114
VEHICLE SPEED SENSOR
REMOVAL............................115
INSTALLATION........................115
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.
RST850 MANUAL TRANSAXLE21-21
ProCarManuals.com

Page 1469 of 2177

CHRYSLER CARAVAN 2003 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

Page 1470 of 2177

CHRYSLER CARAVAN 2003 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 1471 of 2177

CHRYSLER CARAVAN 2003 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 1472 of 2177

CHRYSLER CARAVAN 2003 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

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