2004 CHRYSLER VOYAGER differential

REVERSE GEAR
Engine power is transmitted to the input shaft via
the clutch assembly and the input shaft turns. The
input shaft reverse gear is integral to the input
shaft, and is in constant mesh with the reverse idler
gear. The reverse idler gear, which reverses the rota-
tion of the intermediate shaft, is in constant mesh
with the intermediate shaft reverse gear. Because of
this constant mesh, the intermediate shaft reverse
gear freewheels until reverse gear is selected. As the
gearshift lever is moved to the reverse gear position,
the 5-R fork moves the 5-R synchronizer sleeve
towards the intermediate shaft reverse gear. The
synchronizer sleeve engages the reverse gear clutch
teeth, fixing the gear to the intermediate shaft, and
allowing power to transmit through the intermediate
shaft to the differential (in reverse) (Fig. 9).
DIAGNOSIS AND TESTING - COMMON
PROBLEM CAUSES
The majority of transaxle malfunctions are a result
of:
²Insufficient lubrication
²Incorrect lubricant
²Misassembled or damaged internal components
²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Hard shifting may also be caused by a binding or
broken shift cover mechanism. Remove shift cover
and verify smooth operation. Replace as necessary.
Fig. 9 Reverse Gear Operation
21 - 30 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)

(17) Remove 1-2/5-R shift rail (Fig. 40). (18) Install lifting bar 8489.
(19) Lift geartrain (w/reverse idler gear assy.) out
of transaxle and install on fixture 8487 (Fig. 41).
(20) Remove remaining shift rail and forks from
geartrain (Fig. 41).
(21) Remove lifting bar from geartrain.
NOTE: At this point, differential bearing turning
torque should be measured to ensure proper shim
selection upon reassembly.
(22) Reinstall and torque extension housing and
measure differential turning torque. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS)
(23) Remove differential cover bolts.
(24) Remove differential cover. If necessary, use a
soft tipped hammer to aid in removal.
(25) Remove extension housing.
(26) Remove differential assembly. Note orienta-
tion of shim, oil slinger, and differential side bearing
races (Fig. 42).
Fig. 40 1/2-5/R Shift Rail Removal/Installation
1 - 1/2-5/R SHIFT RAIL
Fig. 41 Shift Fork/Rail Orientation
1 - 5/R FORK
2 - 3/4 RAIL ASSEMBLY
3 - 3/4 FORK
4 - 1/2 FORK
Fig. 42 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
21 - 40 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)

(27) Remove differential chip collector magnet and
clean (Fig. 43).Magnet is adhered with RTV, and
may require force to remove.
(28) Remove intermediate shaft bearing race with
puller 8472 (Fig. 44).(29) Remove shift rail bushing from case with
remover 6786 and slide hammer C-3752 (Fig. 45).
(30) Remove input shaft bearing using an arbor
press and tool 8474 (Fig. 46).
Fig. 43 Differential Magnet
1 - MAGNET
Fig. 44 Intermediate Shaft Bearing Race Removal
1 - REMOVER 8472
Fig. 45 Shift Rail Bushing Removal
1 - SLIDE HAMMER C-3752
2 - REMOVER 6786
RST850 MANUAL TRANSAXLE21-41
T850 MANUAL TRANSAXLE (Continued)

ASSEMBLY
NOTE: When assembling this transaxle, always use
NEW snap rings.
NOTE: Before assembling transaxle, differential
turning torque must be measured and adjusted.
(Refer to 21 - TRANSMISSION/TRANSAXLE/MANU-
AL/DIFFERENTIAL - ADJUSTMENTS). Differential
turning torque must be measured with geartrain out
of case.
(1) Install input shaft bearing using an arbor press
and remover/installer 8474 (Fig. 47).
(2) Install shift shaft bushing to case using
installer 8475 (Fig. 48).
Fig. 46 Input Shaft Bearing Removal
1 - ARBOR PRESS
2 - DRIVER HANDLE C-4171
3 - REMOVER/INSTALLER 8474
Fig. 47 Input Shaft Bearing Installation
1 - ARBOR PRESS
2 - C-4171 DRIVER HANDLE
3 - REMOVER/INSTALLER 8474
4 - INPUT SHAFT BEARING
Fig. 48 Shift Shaft Bushing Installation
1 - INSTALLER 8475
2 - SHIFT SHAFT BUSHING
21 - 42 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)

(23) Install back up lamp switch and torque to 23
N´m (17 ft. lbs.) (Fig. 66).
(24) Roll transaxle assembly on side.
(25) Install differential chip collector magnet (Fig.
67). Retain to case with a dab of MopartGear Lube
RTV.
(26) Install differential assembly with bearing
races and select shim (Fig. 68). Shim selection was
determined before transaxle assembly (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/DIFFER-
ENTIAL - ADJUSTMENTS).
(27) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to differential cover and install to case.
Torque differential cover-to-case bolts to 54 N´m (40
ft. lbs.).(28) Installa1mm(0.04 in.) bead of MopartGas-
ket Maker to extension housing. Install extension
housing to differential cover and case and torque
bolts to 28 N´m (250 in. lbs.) (Fig. 69).
Fig. 66 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 67 Differential Magnet
1 - MAGNET
Fig. 68 Differential Shim/Slinger Orientation
1 - SLINGER
2 - BEARING RACE
3 - DIFFERENTIAL ASSEMBLY
4 - SHIM (SELECT)
Fig. 69 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
21 - 48 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)

INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
(8) Install starter motor into position (Fig. 78).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).(10) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 79). While
depressing inward, rotate slave cylinder clockwise
60tÉ into position until nylon locating tab rests
within transaxle case cutout, and hydraulic tube is
vertical. Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
Fig. 78 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 79 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
RST850 MANUAL TRANSAXLE21-51
T850 MANUAL TRANSAXLE (Continued)

(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 85). While
depressing inward, rotate slave cylinder clockwise
60É into position until nylon locating tab rests within
transaxle case cutout, and hydraulic tube is vertical.
Connect ªquick-connectº connection until an audible
ªclickº is heard. Verify connection by pulling outward
on connection.
(10) Install underbody splash panel.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
86).
(14) Connect gearshift cables to shift levers/cover
assembly (Fig. 87). Install cables into position at
mount bracket and secure with retaining clips.
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 86 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 87 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
21 - 54 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)

SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.65
2nd 2.05 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.77
Overall Top Gear 3.12 2.67
INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
21 - 56 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)