2003 CHRYSLER CARAVAN Service Manual

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Page 1553 of 2177

CHRYSLER CARAVAN 2003 Service Manual (22) Remove 1st gear from shaft (Fig. 248). (23) Remove 1st gear needle bearing (Fig. 249). (24) Remove intermediate shaft roller bearing snap ring (Fig. 250). (25) Press intermediate shaft out of rol

Page 1554 of 2177

CHRYSLER CARAVAN 2003 Service Manual ASSEMBLY NOTE: Depending on date of transaxle manufacture, some intermediate shafts will utilize a needle bear- ing under 2nd and 5th Speed Gears. NOTE: Do not re-use snap rings when servicing the int

Page 1555 of 2177

CHRYSLER CARAVAN 2003 Service Manual (1) Press intermediate shaft into NEW roller bear- ing with arbor press (Fig. 253). (2) Install intermediate shaft roller bearing snap ring (Fig. 254). (3) Install 1st gear roller bearing to intermedi

Page 1556 of 2177

CHRYSLER CARAVAN 2003 Service Manual (7) InstallNEW1/2 synchro snap ring (Fig. 259). (8) Install 2nd gear blocker ring (Fig. 260). Fig. 257 1/2 Synchro on Fixture 8483 1 - FIXTURE 8483 2 - 1ST GEAR BLOCKER RING 3 - 1ST GEAR FRICTION CONE

Page 1557 of 2177

CHRYSLER CARAVAN 2003 Service Manual (9) Install 2nd gear friction cone (Fig. 261). (10) Install 2nd gear reactor ring (Fig. 262). (11) Install 2nd gear and needle bearing (if equipped) to intermediate shaft (Fig. 263). (12) Press 3/4 cl

Page 1558 of 2177

CHRYSLER CARAVAN 2003 Service Manual (13) InstallNEW3/4 cluster gear snap ring (Fig. 265). (14) Install 5th gear and needle bearing (if equipped) to intermediate shaft (Fig. 266).(15) Install 5th gear blocker ring to synchronizer (Fig. 2

Page 1559 of 2177

CHRYSLER CARAVAN 2003 Service Manual (17) InstallNEW5/R synchro snap ring (Fig. 269). (18) Install reverse gear blocker ring (Fig. 270). (19) Install reverse gear needle bearing (Fig. 271). (20) Install reverse gear to intermediate shaft

Page 1560 of 2177

CHRYSLER CARAVAN 2003 Service Manual SHIFT COVER DESCRIPTION The shift cover assembly (Fig. 274) (Fig. 275) is operated by the gearshift crossover and selector cables, and operates the shift fork/shaft system. It consists of crossover an
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