2003 CHRYSLER CARAVAN Service Manual

Page 1545 of 2177

CHRYSLER CARAVAN 2003  Service Manual (7) Install 4th gear blocker ring (Fig. 220).
(8) Install 4th gear and needle bearing (if
equipped) (Fig. 221).
(9) Install 5th gear and press into position using
installer 8481 (Fig. 222).(10) Instal

Page 1546 of 2177

CHRYSLER CARAVAN 2003  Service Manual (11) Stake 5th Gear nut in four (4) places as fol-
lows:
(a) Install staking tool 8479 to 5th gear nut.
(b) Tighten upper thumb screw by hand (Fig.
224).
(c) Tighten two (2) side thumb screws by hand.

Page 1547 of 2177

CHRYSLER CARAVAN 2003  Service Manual INTERMEDIATE SHAFT
DESCRIPTION
The intermediate shaft assembly (Fig. 227) is part
of the transaxle geartrain, meshes with and is driven
by the input shaft, drives the differential via an inte-
grated

Page 1548 of 2177

CHRYSLER CARAVAN 2003  Service Manual (2) Install 8486-4 button to intermediate shaft.
Using arbor press ram, press reverse gear and inter-
mediate roller bearing off of shaft, while holding
remaining assembly with hand (Fig. 228).
(3) Re

Page 1549 of 2177

CHRYSLER CARAVAN 2003  Service Manual (7) Remove 5th gear blocker ring (Fig. 232).
(8) Remove 5th gear and needle bearing (if
equipped) (Fig. 233).(9) Remove 3/4 cluster gear snap ring (Fig. 234).
(10) Install shaft assembly into fixture

Page 1550 of 2177

CHRYSLER CARAVAN 2003  Service Manual (11) Using an arbor press, press intermediate shaft
out of 3/4 cluster gear (Fig. 237).
(12) Remove intermediate shaft from fixture and
remove 3/4 cluster gear from shaft (Fig. 238).
(13) Remove 2nd g

Page 1551 of 2177

CHRYSLER CARAVAN 2003  Service Manual (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).
(17) Remove 1/2 synchro snap ring (Fig. 243).
Fig. 240 2

Page 1552 of 2177

CHRYSLER CARAVAN 2003  Service Manual (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).
(21) Remove 1st gear reactor ring (Fig. 247).
Fig. 244 1/2 Sy