Index Dodge Dodge Neon / Neon SRT-4 - service repair manual 2005 year

Content .. 315 316 317 318 ..

Dodge Neon / Neon SRT-4. Manual - part 317

T850 MANUAL TRANSAXLE

TABLE OF CONTENTS

page

page

T850 MANUAL TRANSAXLE

. . . . . . . . . . . . . . . . . . . . . . . . . 52

. . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DIAGNOSIS AND TESTING - COMMON

. . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

. . . . . . . . . . . . . . . . . . . . . . . . . 66

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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

SPECIFICATIONS - T850 MANUAL

. . . . . . . . . . . . . . . . . . . . . . . . . 85

SPECIAL TOOLS - T850 TRANSAXLE

. . . . . . . . 87

AXLE SEALS

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

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

BACK-UP LAMP SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

. . . . . . . . . . . . . . . . . . . . . . . . . 91

DIFFERENTIAL

. . . . . . . . . . . . . . . . . . . . . . . . . 91

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

. . . . . . . . . . . . . . . . . . . . . . . . . 94

. . . . . . . . . . . . . . . . . . . . . . . . . . 96

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

ADJUSTMENT - DIFFERENTIAL TURNING

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

FLUID

STANDARD PROCEDURE

STANDARD PROCEDURE - FLUID LEVEL

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

STANDARD PROCEDURE - FLUID DRAIN

AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

GEAR SHIFT CABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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

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

GEAR SHIFT MECHANISM

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

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

GEAR SHIFT KNOB

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

. . . . . . . . . . . . . . . . . . . . . . . . 106

INPUT SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 106

. . . . . . . . . . . . . . . . . . . . . . . . 106

. . . . . . . . . . . . . . . . . . . . . . . . . . . 110

INTERMEDIATE SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 114

. . . . . . . . . . . . . . . . . . . . . . . . 114

. . . . . . . . . . . . . . . . . . . . . . . . . . . 123

SHIFT COVER

. . . . . . . . . . . . . . . . . . . . . . . . 129

SHIFT FORK AND SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 130

SYNCHRONIZER

. . . . . . . . . . . . . . . . . . . . . . . . 131

. . . . . . . . . . . . . . . . . . . . . . . . 131

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

. . . . . . . . . . . . . . . . . . . . . . . . . . . 131

. . . . . . . . . . . . . . . . . . . . . . . . . . . 131

VEHICLE SPEED SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

. . . . . . . . . . . . . . . . . . . . . . . . 132

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.

21 - 52

T850 MANUAL TRANSAXLE

PL/SRT-4

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)

PL/SRT-4

T850 MANUAL TRANSAXLE

21 - 53

T850 MANUAL TRANSAXLE (Continued)

The NV T850 transaxle is available with the 2.4L

Turbocharged Engine option. Its gear ratios are as
follows:

GEAR

RATIO

1st

3.65

2nd

2.05

3rd

1.37

4th

0.97

5th

0.76

Reverse

3.47

Final Drive Ratio

3.53

Overall Top Gear Ratio

2.67

TRANSAXLE IDENTIFICATION

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

21 - 54

T850 MANUAL TRANSAXLE

PL/SRT-4

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

PL/SRT-4

T850 MANUAL TRANSAXLE

21 - 55

T850 MANUAL TRANSAXLE (Continued)

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