2003 CHRYSLER VOYAGER cluster

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 SYNCHRONIZER 19 - DIFFERENTIAL ASSEMBLY
4 - 4TH GEAR (SPEED) 12 - 5/R SHIFT FORK 20 - EXTENSION HOUSING
5 - 5TH GEAR (INPUT) 13 - 5TH GEAR (SPEED) 21 - INTERMEDIATE SHAFT BEARING
(CAGED ROLLER)
6 - REVERSE IDLER GEAR 14 - 3/4 CLUSTER GEAR 22 - INTERMEDIATE SHAFT
7 - END COVER, REAR 15 - 2ND GEAR (SPEED) 23 - INPUT SHAFT
8 - INPUT SHAFT BEARING (SEALED
BALL)16 - 1/2 SHIFT FORK 24 - CASE
25 - INPUT SHAFT BEARING (ROLLER)
21 - 22 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

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 freewheelsuntil 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
RST850 MANUAL TRANSAXLE21-27
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

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 gearshiftlever 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
21 - 28 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
ProCarManuals.com

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 pinion gear, and consists of the following com-
ponents:
²Intermediate Mainshaft
²1st Speed Gear
²2nd Speed Gear
²3/4 Cluster Gear
²5th Speed Gear
²Reverse Gear
²1/2 Synchronizer
²5/R Synchronizer
The intermediate shaft is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.DISASSEMBLY
CAUTION: Do not re-use snap rings when servicing
the intermediate shaft assembly. Discard upon dis-
assembly and install new ones provided with avail-
able snap ring service kit.
NOTE: Depending on date of transaxle manufacture,
some intermediate shafts will utilize a needle bear-
ing under the 2nd and 5th Speed Gears.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear.
Fig. 227 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
21 - 100 T850 MANUAL TRANSAXLERS
ProCarManuals.com

(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 8483, with
split collar 8483-3 oriented chamfer side up (Fig.
235). Place 8483-2 into position with chamfer side up
(Fig. 236).
Fig. 232 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 233 5th Gear
1 - 5th GEAR
Fig. 234 3/4 Cluster Gear Snap Ring
1 - SNAP RING
Fig. 235 Fixture 8483
1 - FIXTURE 8483
2 - COLLAR 8483-3
21 - 102 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
ProCarManuals.com

(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 gear and needle bearing (if
equipped) (Fig. 239).
Fig. 236 Loading Intermediate Shaft
1 - FIXTURE 8483
2 - 3/4 CLUSTER GEAR
3 - COLLAR 8483-2
Fig. 237 Press Intermediate Shaft Out of 3/4 Cluster
Gear
1 - ARBOR PRESS RAM
2 - INTERMEDIATE SHAFT
3 - 3/4 CLUSTER GEAR
4 - FIXTURE 8483
Fig. 238 3/4 Cluster Gear
1 - 3/4 CLUSTER GEAR
2 - INTERMEDIATE SHAFT
Fig. 239 2nd Gear Removal
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
RST850 MANUAL TRANSAXLE21 - 103
INTERMEDIATE SHAFT (Continued)
ProCarManuals.com

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
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.NOTE: When installing 1/2 & 5/R synchronizers,
make sure to align oil slots on synchronizer hub
face with oil hold in the shaft splined hub journal.
NOTE: Refer to (Fig. 252) for intermediate shaft
assembly reference.
Fig. 252 Intermediate Shaft Assembly
1 - INTERMEDIATE SHAFT 10 - SNAP RING
2 - ROLLER BEARING 11 - SEALED ROLLER BEARING
3 - SNAP RING 12 - THRUST WASHER
4 - NEEDLE BEARING 13 - NEEDLE BEARING
5 - 1ST SPEED GEAR 14 - REVERSE GEAR
6 - SNAP RING 15 - SNAP RING
7 - 2ND SPEED GEAR 16 - 5/R SYNCHRO
8 - 3/4 CLUSTER GEAR 17 - 5TH SPEED GEAR
9 - SNAP RING 18 - 1/2 SYNCHRO
RST850 MANUAL TRANSAXLE21 - 107
INTERMEDIATE SHAFT (Continued)
ProCarManuals.com

(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 cluster gear onto intermediate shaft
using cup 8481 (Fig. 264).
Fig. 261 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 262 2nd Gear Reactor Ring
1 - 2ND GEAR REACTOR RING
Fig. 263 2nd Gear
1 - 2ND GEAR
2 - INTERMEDIATE SHAFT
Fig. 264 Install 3/4 Cluster Gear using Tool 8481
1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR
21 - 110 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)
ProCarManuals.com