T850 Manual Transaxle: 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 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 1 ).
2. Install shift shaft bushing to case using installer 8475 (Fig 2 ).
   Fig 1: Installing Input Shaft Bearing

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   Fig 2: Installing Shift Shaft Bushing

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3. Install intermediate shaft bearing race to case with an arbor press, driver handle C-4171, and installer 8471 (Fig 3 ). Press until installer 8471 bottoms on transaxle case.
   Fig 3: Installing Intermediate Shaft Bearing Race

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   NOTE: If input shaft assembly was not disassembled, it is necessary to remove input shaft sealed ball bearing before assembling transaxle. (Refer to INPUT SHAFT - DISASSEMBLY  )
4. Install assembled input and intermediate shafts to fixture 8487 (Fig 4 ).
5. Install shift forks and 3/4 rail assembly to geartrain as shown in (Fig 5 ).
   Fig 4: Installing Geartrain To Fixture 8487

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   NOTE: Before installing geartrain, make sure that input shaft sealed roller bearing is not installed, otherwise reverse idler assembly installation will be difficult. (Refer to INPUT SHAFT - DISASSEMBLY  )
6. Install lifting bar 8489 to geartrain. Install geartrain to case. When installing geartrain to case, use care not to damage bearing surfaces. 
7. Remove lifting bar 8489 from geartrain.
8. Install shift 1/2 - 5/R rail as shown in (Fig 6 ).
9. Install reverse idler shaft into position (Fig 7 ). Install and torque shaft-to-case bolt to 54 N.m (40 ft. lbs.).
10. Install reverse idler gear bearing (Fig 8 ).
    Fig 5: Installing Shift Fork And Rail

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    Fig 6: Installing Shift Rail

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    Fig 7: Installing Reverse Idler Shaft

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    Fig 8: Installing Reverse Idler Gear Bearing

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11. Install reverse idler gear with hub down as shown in (Fig 9 ).
    Fig 9: Installing Reverse Idler Gear

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12. Install flat washer (Fig 10 ).
    Fig 10: Installing Flat Washer

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13. Install wave washer (Fig 11 ).
    Fig 11: Installing Wave Washer

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14. Install input shaft sealed roller bearing using installer 8482 (Fig 12 ).
    Fig 12: Installing Input Shaft Sealed Roller Bearing

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15. Install new  input shaft bearing snap ring (Fig 13 ).
    Fig 13: Installing Input Shaft Bearing Snap Ring

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16. Install shift rail bushing to end cover using installer 8475 (Fig 14 ).
    Fig 14: Installing Shift Rail Bushing

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17. Apply a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to transaxle end cover and install to transaxle case (Fig 15 ). While installing end cover, be sure to guide oil trough into pocket ( Fig 16  ).  Torque end cover-to-case bolts to 28 N.m (250 in. lbs.) (Fig 17 ).
    Fig 15: Installing End Cover

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    Fig 16: Locating Oil Trough Pocket

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    Fig 17: Locating End Cover Bolts

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18. Install lifting bar 8489 to geartrain.
19. Lift up on bar (input shaft side) and install input shaft bearing snap ring (Fig 18 ).
20. Lift up on bar (intermediate shaft side) and install intermediate shaft bearing snap ring.
    Fig 18: Installing Input Bearing Snap Ring

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21. Remove lifting bar 8489.
22. Install a bead of Mopar(R) Gear Lube RTV to end plate and immediately install to case. Install and torque bolts to 28 N.m (250 in. lbs.) (Fig 19 ).
    Fig 19: Installing End Cover Bolts

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23. Install back up lamp switch and torque to 23 N.m (17 ft. lbs.) (Fig 20 ).
    Fig 20: Installing Back-Up Lamp Switch

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24. Roll transaxle assembly on side.
25. Install differential chip collector magnet (Fig 21 ). Retain to case with a dab of Mopar(R) Gear Lube RTV.
    Fig 21: Installing Differential Magnet

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26. Install differential assembly with bearing races and select shim (Fig 22 ). Shim selection was determined before transaxle assembly (Refer to DIFFERENTIAL - ADJUSTMENTS  ).
    Fig 22: Installing Differential Shim/Slinger Orientation

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27. Install a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to differential cover and install to case. Torque differential cover-to-case bolts to 54 N.m (40 ft. lbs.).
28. Install a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to extension housing. Install extension housing to differential cover and case and torque bolts to 28 N.m (250 in. lbs.) (Fig 23 ).
    Fig 23: Installing Extension Housing-To-Case Bolts

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29. Install both axle output shaft seals using driver handle C-4171 and installer 8476 (Fig 24 ) (Fig 25 ).
    Fig 24: Installing Axle Seal (Extension Housing Side)

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    Fig 25: Installing Axle Seal - Typical

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30. Install impact blocker (If Equipped) (Fig 26 ).
    Fig 26: Installing Impact Blocker

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31. Apply a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to shift cover assembly. Place shift cover and transaxle geartrain into neutral and install shift cover (Fig 27 ) and torque bolts to 28 N.m (250 in. lbs.).
    Fig 27: Installing Shift Cover

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32. Install input shaft bearing retainer (Fig 28 ). Torque bolts to 12 N.m (105 in. lbs.).
    Fig 28: Installing Input Bearing Retainer

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33. If previously removed, install clutch release lever pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig 29 (Fig 30 ).
    Fig 29: Installing Pivot Ball

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    Fig 30: Identifying Pivot Ball Position

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34. Install clutch release bearing to lever. Apply grease to interface (contact) points. Make sure release bearing retainers engage lever pocket as shown in (Fig 31 ).
    Fig 31: Installing Release Bearing-To-Lever

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35. Apply grease to pivot ball(s), and on release lever at slave cylinder contact point.
36. Install clutch release bearing/lever assembly into position by sliding bearing onto input bearing retainer, and using moderate hand pressure to seat release lever to pivot ball (Fig 32 ). A "pop" sound should be heard. Verify proper engagement by lightly pulling outward on lever at pivot ball location, and then actuating lever and bearing to ensure proper operation.

Fig 32: Installing Release Bearing And Lever

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