2004 CHRYSLER VOYAGER differential

INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear 0.66-1.84 mm (0.026-0.072 in.)
2nd Gear 0.66-1.84 mm (0.026-0.072 in.)
5th Gear 0.86-1.54 mm (0.034-0.061 in.)
Reverse 0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear 0.091-0.828 mm (0.004-0.033 in.)
2nd Gear 0.051-0.787 mm (0.002-0.031 in.)
5th Gear 0.102-0.762 mm (0.004-0.030 in.)
Reverse 0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION METRIC STANDARD
Differential Turning Torque 2.3-3.4 N´m 20-30 in. lbs.
Side Gear End Play (each side) 0.025-0.152 mm 0.001-0.006 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential
Cover-to-Case54 40 Ð
Bolt, End Cover-to-Case 28 Ð 250
Bolt, End Cover
Plate-to-Cover28 Ð 250
Bolt, Extension Housing-
to-Case28 Ð 250
Bolt, Reverse Idler
Shaft-to-Case54 40 Ð
Bolt, Ring Gear-to-
Differential Case95 70 Ð
Bolt, Shift Cover-to-Case 28 Ð 250
Nut, 5th Gear-to-Input
Shaft262 193 Ð
Plug, Drain 23 17 Ð
Screw, Input Bearing
Retainer12 Ð 105
Switch, Back-Up Lamp 23 17 Ð
Vent 7 Ð 60
RST850 MANUAL TRANSAXLE21-57
T850 MANUAL TRANSAXLE (Continued)

AXLE SEALS
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove one or both front halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
(3) Using a suitable screwdriver, remove one or
both axle seals (Fig. 92).
INSTALLATION
(1) Using driver handle C-4171 and installer 8476,
install axle seals into position (Fig. 93) (Fig. 94).
(2) Install one or both front halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(3) Check transaxle fluid level and adjust if neces-
sary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL/FLUID - STANDARD PROCEDURE)
(4) Lower vehicle.
Fig. 92 Axle Seal Removal (Extension Housing Side
Shown)
1 - SCREWDRIVER
2 - AXLE SEAL
3 - EXTENSION HOUSING
Fig. 93 Axle Seal InstallationÐTypical
1 - SEAL
2 - INSTALLER 8476
3 - DRIVER HANDLE C-4171
Fig. 94 Axle Seal Installation (Extension Housing
Side)
1 - EXTENSION HOUSING
2 - SEAL
3 - INSTALLER 8476
4 - DRIVER HANDLE C-4171
RST850 MANUAL TRANSAXLE21-61

BACK-UP LAMP SWITCH
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect back-up lamp switch connector.
(3) Remove back-up lamp switch (Fig. 95).
INSTALLATION
(1) Install back-up lamp switch (Fig. 95) and
torque to 23 N´m (17 ft. lbs.) using Tool 8827.
(2) Connect back-up lamp switch connector.
(3) Lower vehicle.
DIFFERENTIAL
DESCRIPTION
The T850 differential is a conventional open design.
It consists of a ring gear and a two-piece differential
case. The differential case contains the pinion and side
gears, three floating pinion shafts, and a pinion shaft
retaining ring (Fig. 96). The differential case is sup-
ported in the transaxle by tapered roller bearings.
OPERATION
The differential assembly is driven by the interme-
diate shaft via the ring gear. The ring gear drives the
differential case, and the case drives the halfshafts
through the differential gears. The differential pinion
and side gears are supported in the case by pinion
shafts and thrust washers. Differential pinion and
side gears make it possible for front wheels to rotate
at different speeds while cornering.
DISASSEMBLY
(1) Remove differential side bearings:
(a) Install button 8491-1 to differential case (Fig.
97).(b) Set up Tool 5048 (5048-1, -4, -6) as shown in
(Fig. 98).
(c) Remove differential side bearing (Fig. 99).
Same procedure/tools work for both sides.
Fig. 95 Back-Up Lamp Switch
1 - BACK-UP LAMP SWITCH
Fig. 96 Differential Assembly
1 - RING GEAR
2 - SUPPORT PLATE
3 - SIDE GEAR (2)
4 - PINION GEAR (4)
5 - BOLT (12)
6 - PINION SHAFT (2-SHORT)
7 - PINION SHAFT (1-LONG)
8 - THRUST WASHER (2)
9 - RETAINING RING
10 - DIFFERENTIAL CASE
Fig. 97 Tool 8491
1 - TOOL 8491
21 - 62 T850 MANUAL TRANSAXLERS

(2) Remove ring gear-to-case bolts (Fig. 100) and
remove ring gear.
(3) Using three ring gear bolts as forcing screws
(Fig. 101), separate differential support from case
(Fig. 102).
Fig. 98 Puller 5048
1 - 5048-1 FORCING SCREW
2 - 5048-4 COLLETS
3 - 5048-6 SLEEVE
Fig. 99 Differential Side Bearing Removal
1 - TOOL 5048
Fig. 100 Ring Gear-to-Differential Case Bolts
1 - BOLT (12)
2 - DIFFERENTIAL SUPPORT
3 - RING GEAR
Fig. 101 Separate Differential Case Halves
1 - BOLT (3)
2 - DIFFERENTIAL CASE
3 - DIFFERENTIAL SUPPORT
RST850 MANUAL TRANSAXLE21-63
DIFFERENTIAL (Continued)

(4) Remove side gear thrust washer (Fig. 103).(5) Remove side gear (Fig. 104).
(6) Remove long pinion shaft (Fig. 105).
Fig. 102 Differential Support Plate
1 - DIFFERENTIAL SUPPORT PLATE
2 - DIFFERENTIAL CASE
Fig. 103 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
2 - DIFFERENTIAL SIDE GEAR
Fig. 104 Differential Side Gear
1 - DIFFERENTIAL SIDE GEAR
Fig. 105 Long Pinion Shaft
1 - PINION SHAFT (LONG)
21 - 64 T850 MANUAL TRANSAXLERS
DIFFERENTIAL (Continued)

(7) Remove both short pinion shafts (Fig. 106).
(8) Remove pinion shaft retainer (Fig. 107).(9) Remove four pinion gears and thrust washers
(Fig. 108).
(10) Remove side gear (Fig. 109).
Fig. 106 Short Pinion Shaft (2)
1 - PINION SHAFT (SHORT (2))
Fig. 107 Pinion Shaft Retaining Ring
1 - RETAINING RING
Fig. 108 Pinion Gear and Thrust Washer
1 - THRUST WASHER (4)
2 - PINION GEAR (4)
Fig. 109 Differential Side Gear
1 - DIFFERENTIAL SIDE GEAR
RST850 MANUAL TRANSAXLE21-65
DIFFERENTIAL (Continued)

(11) Remove side gear thrust washer (Fig. 110).
ASSEMBLY
(1) Install side gear thrust washer (Fig. 111).(2) Install differential side gear (Fig. 112).
(3) Install four (4) pinion gears and thrust washers
(Fig. 113).
Fig. 110 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
Fig. 111 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
Fig. 112 Differential Side Gear
1 - DIFFERENTIAL SIDE GEAR
Fig. 113 Pinion Gear and Thrust Washer
1 - THRUST WASHER (4)
2 - PINION GEAR (4)
21 - 66 T850 MANUAL TRANSAXLERS
DIFFERENTIAL (Continued)

(4) Install pinion shaft retaining ring (Fig. 114).
(5) Install two (2) short pinion shafts (Fig. 115).(6) Install one (1) long pinion shaft (Fig. 116).
(7) Install differential side gear.
(8) Install side gear thrust washer (Fig. 117).
Fig. 114 Pinion Shaft Retaining Ring
1 - RETAINING RING
Fig. 115 Short Pinion Shaft (2)
1 - PINION SHAFT (SHORT (2))
Fig. 116 Long Pinion Shaft
1 - PINION SHAFT (LONG)
Fig. 117 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
2 - DIFFERENTIAL SIDE GEAR
RST850 MANUAL TRANSAXLE21-67
DIFFERENTIAL (Continued)