2004 CHRYSLER VOYAGER Service Manual

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Page 1705 of 2585

CHRYSLER VOYAGER 2004 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 1706 of 2585

CHRYSLER VOYAGER 2004 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 1707 of 2585

CHRYSLER VOYAGER 2004 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 1708 of 2585

CHRYSLER VOYAGER 2004 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 1709 of 2585

CHRYSLER VOYAGER 2004 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 1710 of 2585

CHRYSLER VOYAGER 2004 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

Page 1711 of 2585

CHRYSLER VOYAGER 2004 Service Manual SYNCHRONIZER DESCRIPTION The T850 transaxle uses two styles of synchronizer assemblies; a conventional single-cone style is used for the 5th/Reverse and 3rd/4th applications (Fig. 277), and a dual-con

Page 1712 of 2585

CHRYSLER VOYAGER 2004 Service Manual VEHICLE SPEED SENSOR REMOVAL (1) Raise vehicle on hoist. (2) Disconnect the speed sensor connector (Fig. 279). CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the
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