2004 CHRYSLER VOYAGER Service Manual

refrigerant type warning light ESP oil capacity fuel additives oil dipstick

Page 1617 of 2585

CHRYSLER VOYAGER 2004 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 1618 of 2585

CHRYSLER VOYAGER 2004 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

Page 1619 of 2585

CHRYSLER VOYAGER 2004 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 1620 of 2585

CHRYSLER VOYAGER 2004 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 1621 of 2585

CHRYSLER VOYAGER 2004 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 1622 of 2585

CHRYSLER VOYAGER 2004 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

Page 1623 of 2585

CHRYSLER VOYAGER 2004 Service Manual 2ND GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft second gear is integral to the input shaft,
and is in constant mesh with the

Page 1624 of 2585

CHRYSLER VOYAGER 2004 Service Manual 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

Load next 8 pages

Page: < prev 1-10 ... 1585-1592 1593-1600 1601-1608 1609-1616 1617-1624 1625-1632 1633-1640 1641-1648 1649-1656 ... 2592 next >

navigation brake pads replacement length cruise control height bolt pattern