Index Chrysler Chrysler RG Voyager - service repair manual 2005 year

Content .. 998 999 1000 1001 ..

Chrysler RG Voyager. Manual - part 1000

T850 MANUAL TRANSAXLE

TABLE OF CONTENTS

page

page

T850 MANUAL TRANSAXLE

. . . . . . . . . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSIS AND TESTING - COMMON

. . . . . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

. . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . . 54

SPECIFICATIONS - T850 MANUAL

. . . . . . . . . . . . . . . . . . . . . . . . . 59

SPECIAL TOOLS - T850 TRANSAXLE

. . . . . . . . 60

AXLE SEALS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

. . . . . . . . . . . . . . . . . . . . . . . . . 63

BACK-UP LAMP SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . 64

DIFFERENTIAL

. . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

ADJUSTMENT - DIFFERENTIAL TURNING

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

ADJUSTMENT - DIFFERENTIAL SIDE GEAR

END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

FLUID

STANDARD PROCEDURE

STANDARD PROCEDURE - FLUID LEVEL

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

STANDARD PROCEDURE - FLUID DRAIN

AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

GEARSHIFT BOOT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

. . . . . . . . . . . . . . . . . . . . . . . . . 75

GEARSHIFT CABLE - CROSSOVER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

. . . . . . . . . . . . . . . . . . . . . . . . . 79

. . . . . . . . . . . . . . . . . . . . . . . . 82

GEARSHIFT CABLE - SELECTOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

. . . . . . . . . . . . . . . . . . . . . . . . . 86

GEARSHIFT KNOB

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

. . . . . . . . . . . . . . . . . . . . . . . . . 90

GEARSHIFT MECHANISM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

. . . . . . . . . . . . . . . . . . . . . . . . . 92

INPUT SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . 95

. . . . . . . . . . . . . . . . . . . . . . . . . 95

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

INTERMEDIATE SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 103

. . . . . . . . . . . . . . . . . . . . . . . . 104

. . . . . . . . . . . . . . . . . . . . . . . . . . . 111

SHIFT COVER

. . . . . . . . . . . . . . . . . . . . . . . . 118

SHIFT FORK AND SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 118

SYNCHRONIZER

. . . . . . . . . . . . . . . . . . . . . . . . 119

. . . . . . . . . . . . . . . . . . . . . . . . 119

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

. . . . . . . . . . . . . . . . . . . . . . . . . . . 119

. . . . . . . . . . . . . . . . . . . . . . . . . . . 119

VEHICLE SPEED SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

. . . . . . . . . . . . . . . . . . . . . . . . 120

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.

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, gradabil-
ity, and acceleration. The gear ratios are as follows:

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T850 MANUAL TRANSAXLE

21 - 21

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 SYNCHRONIZER

19 - DIFFERENTIAL ASSEMBLY

4 - 4TH GEAR (SPEED)

12 - 5/R SHIFT FORK

20 - EXTENSION HOUSING

5 - 5TH GEAR (INPUT)

13 - 5TH GEAR (SPEED)

21 - INTERMEDIATE SHAFT BEARING
(CAGED ROLLER)

6 - REVERSE IDLER GEAR

14 - 3/4 CLUSTER GEAR

22 - INTERMEDIATE SHAFT

7 - END COVER, REAR

15 - 2ND GEAR (SPEED)

23 - INPUT SHAFT

8 - INPUT SHAFT BEARING (SEALED
BALL)

16 - 1/2 SHIFT FORK

24 - CASE

25 - INPUT SHAFT BEARING (ROLLER)

21 - 22

T850 MANUAL TRANSAXLE

RS

T850 MANUAL TRANSAXLE (Continued)

GEAR

RATIO

1st

3.65

2nd

2.05

3rd

1.37

4th

0.97

5th

0.76

Reverse

3.47

Final Drive Ratio

3.77

Overall Top Gear

2.85

TRANSAXLE IDENTIFICATION

NOTE: Since transaxles use unique gear ratios for
each of the two engine applications, it is imperative
that the transaxle is properly identified, and the cor-
rect transaxle assembly number is used when
ordering service parts.

The transaxle model, assembly part number, build

date, and final drive ratio (FDR) can be found on a
metal tag fastened to the transaxle case on the bell-
housing (Fig. 2). A barcode label is also glued to the
transaxle bellhousing, and it too includes the trans-
axle part number.

Fig. 2 T850 Transaxle Identification

1 - TRANSAXLE BELLHOUSING
2 - BARCODE LABEL
3 - I.D. TAG

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T850 MANUAL TRANSAXLE

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T850 MANUAL TRANSAXLE (Continued)

OPERATION

NEUTRAL

Engine power is transmitted to the tinput shaft.

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 is not transmitted to the
intermediate shaft and the differential does not turn
(Fig. 3).

Fig. 3 Neutral Gear Operation

21 - 24

T850 MANUAL TRANSAXLE

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T850 MANUAL TRANSAXLE (Continued)

Content .. 998 999 1000 1001 ..