2004 CHRYSLER VOYAGER lock

(7) Remove oil filter (Fig. 334).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 335).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 336) (Fig.
337).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
DISASSEMBLY
NOTE: If valve body assembly is being recondi-
tioned, the PCM/TCM Quick Learn Procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
Fig. 334 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 335 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 336 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 337 Valve Body Removal/Installation
1 - VALVE BODY
21 - 252 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

NOTE: 5th gear nut is staked to the shaft. If neces-
sary, grind stake area to ease removal, but use care
not to contact gear.(5) Remove 5th gear nut with wrench 8478 (Fig.
4). Discard nut and use a new one upon assembly.
(6) Remove 5th gear with arbor press and bearing
splitter. (7) Remove 4th gear and needle bearing (Fig. 5)
(Fig. 6). (8) Remove 4th gear blocker ring (Fig. 7).
Fig. 4 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
Fig. 5 4th Gear Removal/Installation
1 - 4TH GEAR
2 - NEEDLE BEARING
Fig. 6 4th Gear Needle Bearing Removal/Installation
1 - 4TH GEAR NEEDLE BEARING
Fig. 7 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
RS
T850 MANUAL TRANSAXLE21s-3
INPUT SHAFT (Continued)

(9) Remove 3/4 synchronizer snap ring (Fig. 8).
Discard and replace with new snap ring upon assem-
bly.
(10) Remove 3/4 synchronizer (Fig. 9). (11) Remove 3rd gear blocker ring (Fig. 10).
(12) Remove 3rd gear and needle bearing (Fig. 11)
(Fig. 12).
(13) Inspect third gear thrust washer for signs of
excessive wear. To replace, drive off of input shaft
with suitable drift and hammer.
Fig. 8 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 9 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
Fig. 10 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 11 3rd Gear Removal/Installation
1 - 3RD GEAR
2 - NEEDLE BEARING
21s - 4 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)

(3) Install 3rd gear and needle bearing (Fig. 14)
(Fig. 15). (4) Install 3rd gear blocker ring (Fig. 16).
(5) Install 3/4 synchronizer (Fig. 17).
When
installing 3/4 synchronizer hub to shaft, make
sure to align oil slots on synchronizer hub face
with oil hole in the shaft splined hub journal.
Fig. 14 3rd Gear Needle Bearing Removal/ Installation
1 - 3RD GEAR NEEDLE BEARING
2 - THRUST WASHER
Fig. 15 3rd Gear Removal/Installation
1 - 3RD GEAR
2 - NEEDLE BEARING
Fig. 16 3rd Gear Blocker Ring
1 - 3RD GEAR BLOCKER RING
Fig. 17 3/4 Synchro Assembly
1 - 3/4 SYNCHRONIZER
21s - 6 T850 MANUAL TRANSAXLERS
INPUT SHAFT (Continued)

(6) InstallNEW3/4 synchronizer snap ring (Fig.
18).
(7) Install 4th gear blocker ring (Fig. 19). (8) Install 4th gear and needle bearing (Fig. 20)
(Fig. 21).
Fig. 18 3/4 Synchro Snap Ring
1 - SNAP RING
2 - 3/4 SYNCHRONIZER
Fig. 19 4th Gear Blocker Ring
1 - 4th GEAR BLOCKER RING
Fig. 20 4th Gear Needle Bearing Removal/ Installation
1 - 4TH GEAR NEEDLE BEARING
Fig. 21 4th Gear Removal/Installation
1 - 4TH GEAR
2 - NEEDLE BEARING
RS T850 MANUAL TRANSAXLE21s-7
INPUT SHAFT (Continued)

²1/2 Synchronizer
² 5/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.
(1) Install intermediate shaft assembly to arbor
press table with bearing splitter P-334 under the
reverse gear. (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. 28). (3) Remove reverse gear blocker ring.
(4) Remove reverse gear needle bearing (Fig. 29).
(5) Remove 5/R synchro snap ring (Fig. 30).
Fig. 28 Bearing and Reverse Gear Removal
1 - ARBOR PRESS RAM
2 - ADAPTER
3 - SEALED ROLLER BEARING
4 - REVERSE GEAR
5 - BEARING SPLITTER P-334
Fig. 29 Reverse Gear Needle Bearing
1 - NEEDLE BEARING
Fig. 30 5/R Synchro Snap Ring
1 - SNAP RING
21s - 10 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)

(6) Remove 5/R synchro (Fig. 31).
(7) Remove 5th gear blocker ring (Fig. 32).(8) Remove 5th gear and needle bearing (Fig. 33)
(Fig. 34).
Fig. 31 5/R Synchronizer
1 - 5/R SYNCHRO ASSEMBLY
Fig. 32 5th Gear Blocker Ring
1 - 5th GEAR BLOCKER RING
Fig. 33 5th Gear Removal/Installation
1 - 5TH GEAR
2 - NEEDLE BEARING
Fig. 34 5th Gear Needle Bearing Removal/ Installation
1 - 5TH GEAR NEEDLE BEARING
RS T850 MANUAL TRANSAXLE21s-11
INTERMEDIATE SHAFT (Continued)

(15) Remove 2nd gear friction cone (Fig. 43).
(16) Remove 2nd Gear outer blocker ring (Fig. 44).(17) Remove 1/2 synchro snap ring (Fig. 45).
(18) Remove 1/2 synchro from shaft (Fig. 46).
Fig. 43 2nd Gear Friction Cone
1 - 2ND GEAR FRICTION CONE
Fig. 44 2nd Gear Outer Blocker Ring
1 - 2ND GEAR BLOCKER RING
Fig. 45 1/2 Synchro Snap Ring
1 - SNAP RING
2 - 1/2 SYNCHRO HUB
Fig. 46 1/2 Synchronizer
1 - 1/2 SYNCHRONIZER
21s - 14 T850 MANUAL TRANSAXLERS
INTERMEDIATE SHAFT (Continued)