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(7) Remove input shaft bearing retainer bolts from the front housing, then carefully pry on the retainer to break sealer bead loose (Fig. 8).
Fig.10INPUTSHAFTSNAPRING
1 - INPUT SHAFT SNAP RING 2 - OIL FEED
Fig.8BEARINGRETAINERSEAL
1 - PRY TOOL 2 - INPUT SHAFT BEARING RETAINER
21 - 6 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(10) Remove shift shaft detent plug from the side of the transmission with Remover 8117A. Attach fin- gers of the remover to the detent plug and push the cup down till it contacts the trans. Then tighten the nut till it pulls the plug from the case.
(11) Remove shift shaft detent plunger and spring
with a pencil magnet.
(12) Remove bolts that attach front housing to the rear housing (Fig. 11). Three bolts at extreme rear of housing are for the output shaft bearing retainer. Leave one bolt in place until geartrain is ready to be removed from case.
(13) Separate the housings (Fig. 12) by tapping the front housing off alignment dowels with a plastic hammer.
Fig.12FRONTHOUSING
1 - FRONT HOUSING 2 - REAR HOUSING 3 - DOWELS (2) 4 - PLASTIC MALLET
(14) Remove input shaft bearing and countershaft
front bearing race (Fig. 13).
Fig.11HOUSING&BEARINGRETAINERBOLT
1 - RETAINER BOLTS 2 - HOUSING BOLTS 3 - RETAINER BOLT 4 - HOUSING BOLT LOCATIONS
Fig.13InputShaftBearingandCountershaftFront
BearingRace
1 - INPUT SHAFT BEARING 2 - FRONT HOUSING 3 - COUNTERSHAFT FRONT BEARING
DR MANUAL TRANSMISSION - NV3500 (Continued)
(15) Note position of input shaft, shift shaft, forks
and geartrain components in housing (Fig. 14).
MANUAL TRANSMISSION - NV3500
21 - 7
Fig.15DETENTSPRINGANDBALL
1 - SHAFT LEVER 2 - SPRING AND BALL 3 - MAGNET
Fig.16SHIFTSOCKET
1 - REMOVER 2 - SHIFT SOCKET
Fig.14GEARTRAINANDSHIFTCOMPONENT
1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER AND SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT 7 - 1-2 FORK 8 - INPUT SHAFT 9 - 3-4 FORK
SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT
(1) Place a shop towel over the shaft lever to con-
tain the lever detent ball and spring.
(2) Rotate lever and bushing upward out of the
shift forks and catch ball and spring (Fig. 15).
(3) Unseat shift socket roll pin with Remover 6858. Position remover on shift shaft and center tool over the roll pin. Verify tool legs are firmly seated on the shift socket (Fig. 16).
(4) Tilt socket toward the side of the case to avoid
trapping the pin between the gear teeth.
(5) Tighten remover to press the roll pin down-
ward and out of the shift socket (Fig. 16).
NOTE: Roll pin must only clear the shift shaft. Do not push the pin into the geartrain.
(6) Drive out shift bushing and lever roll pin with
a hammer and punch (Fig. 17).
NOTE: Use proper size punch to avoid bending the shift shaft.
Fig.17SHIFTSHAFTLEVER&BUSHINGROLLPIN 1 - PIN PUNCH 2 - BUSHING AND LEVER 3 - SHIFT SHAFT
21 - 8 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(7) Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork and 1-2 fork (Fig. 18).
(10) Rotate 3-4 fork around synchro sleeve until fork clears shift arms on 1-2 and fifth-reverse forks, then remove 3-4 fork (Fig. 21).
Fig.18SHIFTSHAFT
1 - SHIFT SHAFT 2 - 3-4 FORK 3 - SHAFT DETENT NOTCHES
(8) Remove shift socket from rear housing (Fig. 19).
Fig.213-4SHIFTFORK
1 - 3-4 FORK 2 - 1-2 AND 5TH-REVERSE FORK ARMS 3 - 3-4 SYNCHRO SLEEVE
(11) Remove reverse idler shaft support bolt and
loosen rear reverse idler shaft bolt (Fig. 22).
Fig.19SHIFTSOCKET&ROLLPIN
1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET
(9) Remove shaft lever and bushing (Fig. 20).
Fig.20SHIFTSHAFTLEVER&BUSHING
1 - SHAFT LEVER AND BUSHING 2 - 3-4 FORK
Fig.22REVERSEIDLERSHAFT&SUPPORT
1 - SUPPORT BOLT 2 - SHAFT BOLT
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 9
(12) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(13) Support geartrain and rear housing on Fix-
ture 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2A on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 23).
(d) Stand geartrain and rear housing upright on fixture (Fig. 24). Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position.
Fig.23FIXTUREASSEMBLY
1 - FIXTURE 6747
2 - ADAPTER 6747-1A 3 - CUP ADAPTER 8115
4 - REVERSE IDLER PEDESTAL 5 - ADAPTER 6747-2A(14) Remove rear bolt holding reverse idler shaft
in housing.
REAR HOUSING - 2WD
(1) On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (Fig. 25). Bolts are rear of shift tower open- ing.
Fig.24GEARTRAIN&HOUSINGONFIXTURE
1 - INPUT SHAFT 2 - COUNTERSHAFT 3 - FIXTURE 6747
Fig.25OUTPUTSHAFT
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT IS AT OPPOSITE SIDE OF CASE)
21 - 10 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(2) Tap rear housing upward and off output shaft
bearing with a plastic/rawhide hammer (Fig. 26).
DR
Fig.26SEPARATEREARHOUSING&OUTPUT
SHAFTBEARING
1 - REAR HOUSING 2 - MALLET 3 - FIXTURE
(3) Lift rear housing up and off geartrain (Fig. 27). (4) Remove countershaft rear bearing from coun-
tershaft (Fig. 28).
Fig.27REARHOUSING-2WD
1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN
Fig.28COUNTERSHAFTREARBEARING
1 - COUNTERSHAFT REAR BEARING 2 - OUTPUT SHAFT 3 - COUNTER SHAFT
DR MANUAL TRANSMISSION - NV3500 (Continued) REAR ADAPTER HOUSING - 4WD
(1) Inserting screw from slide hammer (Fig. 29) into one of the dimples in face of rear seal (Fig. 30) and remove seal.
MANUAL TRANSMISSION - NV3500
21 - 11
(2) Remove rear bearing snap ring from output
shaft (Fig. 31).
Fig.29REARSEAL
1 - SLIDE HAMMER 2 - REMOVER TOOL 3 - REAR SEAL
Fig.31REARBEARINGSNAPRING
1 - HEAVY DUTY SNAP RING PLIERS 2 - REAR BEARING SNAP RING 3 - OUTPUT SHAFT
(3) Lift rear adapter housing upward and off
geartrain (Fig. 32).
Fig.30REARSEALFACE
1 - DIMPLES 2 - SEAL FACE
Fig.32REARADAPTERHOUSING
1 - REAR ADAPTER HOUSING 2 - OUTPUT SHAFT
21 - 12 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(4) Remove bearing retainer bolts and remove rear bearing retainer and rear bearing (Fig. 33). Push or tap bearing out of housing with a hammer handle if needed.
NOTE: Housing must be replaced if race, bearing bore or idler shaft notch are worn or damaged.
(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Position Bearing Splitter 1130 between second and third gears and press off 3-4 synchro assembly, third gear synchro ring and third gear with a shop press.
(3) Remove third gear needle bearing (Fig. 34).
Fig.34THIRDGEARNEEDLEBEARING
1 - THIRD GEAR NEEDLE BEARING
(4) Remove retaining ring that secures two-piece thrust washer on shaft with a small pry tool (Fig. 35).
Fig.33REARADAPTERHOUSINGCOMPONENTS 1 - BEARING RETAINER 2 - RETAINER BOLTS (3) 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT REAR BEARING RACE 5 - REAR BEARING
GEARTRAIN FROM FIXTURE
(1) Remove reverse idler gear assembly from
assembly fixture cup.
chro sleeves.
(2) Remove 1-2 and fifth-reverse forks from syn-
(3) Slide countershaft out of fixture tool. (4) Remove output shaft bearing retainer from rear surface of fifth gear (retainer will drop onto gear after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from the fixture.
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different and must not be mixed. Remove each synchronizer unit as an assembly to avoid mixing parts. Mark each synchro hub and sleeve with a scriber or paint for correct assembly reference.
Fig.35THRUSTWASHER
1 - PRY TOOL 2 - THRUST WASHER RETAINING RING
DR MANUAL TRANSMISSION - NV3500 (Continued)
(5) Remove two-piece thrust washer (Fig. 36) and note position of washer locating lugs in shaft notches for installation reference.
MANUAL TRANSMISSION - NV3500
21 - 13
Fig.38SECONDGEARSYNCHRORING&CONES 1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - INTERM RING 3 - SYNCHRO FRICTION CONE 4 - SYNCHRO CONE 5 - SYNCHRO RING
Fig.36TWO-PIECETHRUSTWASHER
1 - SECOND GEAR 2 - THRUST WASHER (2-PIECE) 3 - WASHER LOCATING LUG
(6) Remove second gear and needle bearing (Fig.
37).
Fig.39HUBSLEEVE&1-2SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - BEARING SPLITTER 1130
Fig.37SECONDGEAR
1 - SECOND GEAR 2 - SECOND GEAR NEEDLE BEARING
(7) Remove second gear synchro ring, synchro fric-
tion cone, synchro cone and interm ring (Fig. 38).
(8) Remove 1-2 synchro hub snap ring. (9) Position Bearing Splitter 1130 between first and reverse gear. Press off 1-2 synchro hub, sleeve and first gear from output shaft with shop press (Fig. 39).
(10) Remove first gear needle bearing (Fig. 40).
Fig.40FIRSTGEARNEEDLEBEARING
1 - FIRST GEAR NEEDLE BEARING
21 - 14 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(11) Remove output shaft bearing snap ring (Fig. 41).
(15) Remove fifth-reverse synchro hub snap ring
(Fig. 44).
Fig.41OUTPUTSHAFTBEARINGSNAPRING
1 - OUTPUT SHAFT BEARING 2 - BEARING SNAP RING 3 - SNAP RING PLIERS
(12) On 2-wheel drive models, remove output shaft
bearing.
(13) Remove fifth gear (Fig. 42).
Fig.44FIFTH-REVERSESYNCHROHUBSNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 2 - SYNCHRO HUB SNAP RING 3 - SNAP RING PLIERS
(16) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 45).
Fig.42FIFTHGEAR
1 - FIFTH GEAR AND SYNCHRO RING
(14) Remove fifth gear needle bearing. Spread bearing
just enough to clear shoulder on output shaft (Fig. 43).
Fig.43FIFTHGEARNEEDLEBEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig.45FIFTH-REVERSESYNCHRO
1 - PRESS 2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 3 - REVERSE GEAR 4 - OUTPUT SHAFT
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 15
(17) Remove reverse gear and needle bearing (Fig.
46).
INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball or internal components are worn or damaged.
SHIFT SHAFT AND FORKS
Fig.46REVERSEGEAR&NEEDLEBEARING
1 - REVERSE GEAR AND NEEDLE BEARING
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47). (2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and transmission housings with a standard parts clean- ing solvent. Do not use acid or corrosive base sol- vents. Dry all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk or similar sol- vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
Inspect the shift fork interlock arms and synchro sleeve contact surfaces (Fig. 48). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks.
Check condition of the shift shaft detent plunger and spring. The plunger should be smooth and free of nicks or scores. The plunger spring should be straight and not collapsed, or distorted. Minor scratches or nicks on the plunger can be smoothed with 320/400 grit emery soaked in oil. Replace the plunger and spring if in doubt about condition. Check condition of detent plunger bushings. Replace if dam- aged.
Inspect shift shaft, shift shaft bushing, bearing, shaft lever and lever bushing that fits over the lever. Replace shaft if bent, cracked or severely scored. Minor burrs, nicks or scratches can be smoothed off with 320/400 grit emery cloth followed by polishing with crocus cloth. Replace the shift shaft bushing or bearing if damaged.
Replace the shaft lever and bushing if either part is deformed, or worn. Do not attempt to salvage these parts as shift fork binding will occur. Replace the roll pin that secures the lever to the shaft.
1 - SNAP RING 2 - FLAT WASHER 3 - WAVE WASHER 4 - THRUST WASHER 5 - REVERSE IDLER GEAR
Fig.47ReverseIdlerComponents
6 - IDLER GEAR BEARING 7 - IDLER SHAFT 8 - THRUST WASHER 9 - SNAP RING 10 - THRUST WASHER LOCKBALLS
21 - 16 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
1 - SHIFT SHAFT 2 - SHAFT LEVER 3 - SHAFT LEVER BUSHING
Fig.48ShiftForksAndShaft
4 - 3-4 SHIFT FORK 5 - 1-2 SHIFT FORK 6 - FIFTH-REVERSE SHIFT FORK
FRONT/REAR HOUSINGS AND BEARING RETAINERS
Inspect the housings carefully. Look for cracks, stripped threads, scored mating surfaces, damaged bearing bores or worn dowel pin holes. Minor nicks on mating surfaces can be dressed off with a fine file or emery cloth. Damaged threads can be renewed by either re-tapping or installing Helicoil inserts.
NOTE: The front housing contains the countershaft front bearing race. The rear housing contains the countershaft rear bearing race. These components are NOT serviceable items. The front housing will have to be replaced if the countershaft bearing race is loose, worn or damaged. The rear housing will have to be replaced if the countershaft rear bearing race is loose, worn or damaged.
Inspect the input shaft bearing retainer. Be sure the release bearing slide surface of the retainer is in good condition. Minor nicks on the surface can be smoothed off with 320/420 grit emery cloth and final polished with oil coated crocus cloth. Replace the retainer seal if necessary. shaft
the U-shaped retainer must be flat and free of distortion. Replace the retainer if the threads are damaged or if the retainer is bent or cracked.
retainer,
bearing
Inspect
output
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine lapped during manufacture to form matched sets. The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit in the housings and are NOT serviceable. If a bear- ing race becomes damaged, the front or rear hous- ing must be replaced. A new countershaft bearing will be supplied with each new housing for service use.
REVERSE IDLER COMPONENTS
Inspect
the idler gear, bearing,
thrust washer, wave washer and thrust plate. Replace the bearing if any of the needle bearing rollers are worn, chipped, cracked, flat-spotted or brinnelled. Also replace the bearing if the plastic bearing cage is damaged or distorted.
shaft,
Replace thrust washer, wave washer or thrust plate if cracked, chipped or worn. Replace idler gear if the teeth are chipped, cracked or worn thin. Replace shaft if worn, scored or the bolt threads are damaged beyond repair. Replace support segment if cracked or chipped and replace the idler attaching bolts if the threads are damaged.
DR MANUAL TRANSMISSION - NV3500 (Continued) Shift Socket
MANUAL TRANSMISSION - NV3500
21 - 17
Inspect
the shift socket
for wear or damage. Replace the socket if the roll pin or shift shaft bores are damaged. Minor nicks in the shift lever ball seat in the socket can be smoothed down with 400 grit emery or wet/dry paper. Replace the socket if the ball seat is worn or cracked. Do not reuse the original shift socket roll pin. Install a new pin during assem- bly. The socket roll pin is approximately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro- ken teeth. Also check condition of the bearing bore in each gear. The bores should be smooth and free of surface damage. Discoloration of the gear bores is a normal occurrence and is not a reason for replace- ment. Replace gears only when tooth damage has occurred or if the bores are brinnelled or severely scored.
Inspect the shaft splines and bearings surfaces. Minor nicks on the bearing surfaces can be smoothed with 320/420 grit emery and final polished with cro- cus cloth. Replace the shaft if the splines are dam- aged or bearing surfaces are deeply scored, worn or brinnelled.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use Mopar Gasket Maker or equivalent for all case joints and Mopar silicone sealer or equivalent for the input shaft bearing retainer.
SYNCHRONIZER
(1) Slide sleeve onto the hub, leaving enough room to install the spring in the hub and strut in the hub groove.
(2) Install first spring in the hub, then install a strut over the spring. Verify spring is seated in the spring bore in the strut.
(3) Slide sleeve onto the hub far enough to hold
the first strut and spring in place.
(4) Place detent ball in the top of the strut, then press the ball into place with a small screwdriver. Work the sleeve over the ball to hold it in place.
(5) Repeat procedure for the remaining springs, struts and balls. Use tape or rubber bands to tempo- rarily secure each strut and ball as they are installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 49).
Fig.49SYNCHRONIZERCOMPONENTS
1 - SLEEVE 2 - HUB SHOULDER 3 - SPRING (3) 4 - STRUT (3) 5 - DETENT BALL (3) 6 - HUB
OUTPUT SHAFT
shaft, gears, bearings
and NOTE: Lubricate immerse each synchro ring with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.
(1) Install reverse gear needle bearing up against
shoulder on output shaft (Fig. 50).
Fig.50REVERSEGEARBEARING
1 - REVERSE GEAR BEARING 2 - SHOULDER
21 - 18 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(2) Install reverse gear over needle bearing (Fig.
51).
DR
Fig.51REVERSEGEAR
1 - REVERSE GEAR
(3) Install brass synchro ring on reverse gear (Fig.
52).
Fig.52REVERSEGEARSYNCHRO
1 - REVERSE GEAR 2 - SYNCHRO RING
(4) Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover 6310-1 (Fig. 53).
CAUTION: One side of the hub has shoulders around the hub bore, this side faces the front of the shaft. One side of the sleeve is tapered the tapered side faces the front of the shaft.
(5) Install new fifth-reverse hub snap ring (Fig.
54). Verify snap ring is seated in the groove.
Fig.53FIFTH/REVERSESYNCHROASSEMBLY
1 - SPACER 2 - PRESS RAM 3 - REVERSE GEAR 4 - FIFTH-REVERSE SYNCHRO ASSEMBLY 5 - REMOVER 6310-1
6 - PRESS BLOCKS 7 - OUTPUT SHAFTFig.54FIFTH/REVERSESYNCHROHUBSNAPRING 1 - FIFTH-REVERSE SYNCHRO ASSEMBLY 2 - SNAP RING 3 - PRESS BED 4 - PRESS BLOCKS
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 19
(6) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 55).
(8) Install fifth gear on shaft and onto bearing
(Fig. 57).
Fig.55FIFTHGEARSYNCHRORING
1 - FIFTH-SPEED SYNCHRO RING 2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
1 - FIFTH GEAR 2 - BEARING
Fig.57FIFTHGEAR
(7) Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft (Fig. 56). Verify bearing is properly seated.
(9) Invert output shaft and set the shaft in Collar
6310-1 so fifth gear is seated on the tool (Fig. 58).
(10) Install first gear bearing on output shaft (Fig. 58). Verify bearing is seated on shaft shoulder and is properly joined.
Fig.56FIFTHGEARBEARING
1 - SHAFT SHOULDER 2 - FIFTH GEAR BEARING
Fig.58FIRSTGEAR
1 - FIRST GEAR BEARING 2 - SHAFT SHOULDER 3 - COLLAR 4 - PRESS BLOCKS
21 - 20 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(11) Install first gear on shaft and over bearing
(Fig. 59) with bearing synchro cone facing up.
DR
Fig.59FIRSTGEAR
1 - FIRST GEAR 2 - COLLAR 3 - BEARING
(12) Install first gear synchro ring (Fig. 60).
Fig.61STARTING1-2SYNCHRO
1 - 1-2 SYNCHRO ASSEMBLY 2 - COLLAR 3 - FIRST GEAR SIDE
Fig.60FIRSTGEARSYNCHRORING
1 - FIRST GEAR SYNCHRO RING 2 - COLLAR 3 - FIRST GEAR
(13) Start 1-2 synchro assembly on shaft by hand
(Fig. 61).
CAUTION: One side of the synchro sleeve is marked First Gear Side, this side must face first gear.
(14) Press 1-2 synchro onto output shaft using
suitable size pipe and shop press (Fig. 62).
CAUTION: Keep synchro ring and sleeve aligned as the hub is being pressed onto the shaft. The syn- chro ring can be cracked if it becomes misaligned.
Fig.621-2SYNCHROONOUTPUTSHAFT
1 - PIPE TOOL 2 - SYNCHRO RING 3 - COLLAR 4 - 1-2 SYNCHRO ASSEMBLY 5 - PRESS RAM
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 21
(15) Install interm ring. (16) Install new 1-2 synchro hub snap ring (Fig.
63). Verify snap ring is seated in shaft groove.
(19) Install second gear needle bearing on shaft
(Fig. 65).
Fig.631-2SYNCHROHUBSNAPRING
1 - 1-2 SYNCHRO 2 - COLLAR 3 - SYNCHRO SNAP RING
(17) Install second gear synchro ring in 1-2 syn- chro hub and sleeve (Fig. 64). Verify synchro ring is seated in sleeve.
(18) Install synchro friction cone and synchro cone
in synchro ring.
Fig.65SECONDGEARBEARING
1 - SECOND GEAR BEARING 2 - COLLAR
(20) Install second gear onto shaft and bearing (Fig. 66). Verify second gear is seated on synchro components.
Fig.64SECONDGEARSYNCHRORING
1 - SECOND GEAR SYNCHRO RING 2 - 1-2 SYNCHRO 3 - COLLAR
Fig.66SECONDGEAR
1 - COLLAR 2 - 1-2 SYNCHRO ASSEMBLY 3 - BEARING 4 - SECOND GEAR
21 - 22 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(21) Install two-piece thrust washer with halves seated in the shaft groove and washer lugs seated in shaft lug bores (Fig. 67). Verify i.d. grooves and markings noted during removal are facing the correct direction.
DR
Fig.68RETAININGRING
1 - THRUST WASHER RETAINING RING 2 - THRUST WASHER HALVES 3 - SECOND GEAR 4 - LOCATING DIMPLE
Fig.67TWO-PIECETHRUSTWASHER
1 - WASHER GROOVE IN SHAFT 2 - LUG BORE 3 - THRUST WASHER LUGS 4 - LUG BORE 5 - LUG 6 - WASHER HALF
Fig.69THRUSTRETAINER
1 - PLASTIC MALLET 2 - THRUST WASHER RETAINING RING
(22) Start retaining ring around two-piece thrust washer (Fig. 68). Verify locating dimple is between thrust washer halves.
(23) Seat thrust washer retaining ring with plastic
mallet (Fig. 69).
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 23
(24) Install third gear needle bearing on shaft (Fig.
70).
(26) Install third speed synchro ring on third gear
(Fig. 72).
Fig.70THIRDGEARBEARING
1 - THIRD GEAR BEARING
(25) Install third gear on shaft and bearing (Fig.
71).
Fig.72THIRDGEARSYNCHRORING
1 - THIRD SPEED SYNCHRO RING 2 - THIRD GEAR
(27) Start 3-4 synchro hub on output shaft splines
by hand (Fig. 73).
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has grooves in it, this side must faces the front of the shaft.
Fig.71THIRDGEAR
1 - THIRD GEAR 2 - BEARING
Fig.733-4SYNCHROHUBONOUTPUTSHAFT
1 - GROOVED SIDE OF SLEEVE 2 - 3-4 SYNCHRO ASSEMBLY
21 - 24 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(28) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to output shaft as possible but not contacting the shaft splines.
(30) Install output shaft bearing. (31) Install output shaft bearing snap ring with heavy duty snap ring pliers (Fig. 76). Verify snap ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
Fig.76OUTPUTSHAFTBEARINGSNAP
1 - BEARING SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS
(32) Verify position of synchro sleeves before pro- ceeding (Fig. 77). Grooved side of 3-4 sleeve must face forward. First gear side of 1-2 sleeve must face first gear. Tapered side of fifth-reverse sleeve must face forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube. (2) Slide idler gear bearing on shaft (Fig. 78).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 78).
(4) Place first lock ball in dimple at rear end of idler shaft (Fig. 78). Petroleum jelly can be used to hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 79).
(6) Install snap ring in groove at rear of shaft (Fig.
79).
Fig.743-4SYNCHROONOUTPUTSHAFT
1 - PRESS RAM 2 - PIPE TOOL 3 - 3-4 SYNCHRO 4 - THIRD SPEED SYNCHRO RING
(29) Install new 3-4 synchro hub snap ring (Fig.
75). Verify snap ring is seated in groove.
Fig.753-4SYNCHROHUBSNAPRING
1 - 3-4 SYNCHRO HUB SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 25
Fig.77SYNCHROSLEEVELOCATIONS
1 - DOUBLE GROOVE FORWARD 2 - GROOVE FORWARD 3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 4 - TAPER FORWARD
5 - GROOVE FORWARD 6 - 5TH-REV SYNCHRO SLEEVE 7 - 1-2 SYNCHRO SLEEVE 8 - 3-4 SYNCHRO SLEEVE
Fig.78IDLERGEAR&BEARING
1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT
Fig.79IDLERGEARREARTHRUSTWASHER
1 - LOCK BALL 2 - SNAP RING GROOVE 3 - THRUST WASHER
21 - 26 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
(8) Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 80). (9) Install wave washer, flat washer and remain- ing snap ring on idler shaft (Fig. 80). Verify snap ring is seated.
Fig.80IDLERGEAR&SHAFTASSEMBLY
1 - REAR OF SHAFT 2 - GEAR 3 - THRUST WASHER AND BALL 4 - WAVE WASHER 5 - FLAT WASHER 6 - FRONT OF SHAFT 7 - SNAP RING 8 - SNAP RING
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/ BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
replaced as follows:
(2) If necessary, the shift shaft bushing can be
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.
(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.
(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case. (3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case. (4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to a specific depth. The space between the two bush- ings when correctly installed contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
the case.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
DR MANUAL TRANSMISSION - NV3500 (Continued) GEARTRAIN ASSEMBLY
MANUAL TRANSMISSION - NV3500
21 - 27
(4) Install fourth gear synchro ring on input shaft
(Fig. 83).
(1) Install Adapter 6747-1A on input shaft hub of Fixture 6747 (Fig. 81). Then install Adapter 6747-2A on front bearing hub of countershaft. Be sure the shoulder is seated against the countershaft.
Fig.81FIXTUREFORGEARTRAINBUILD-UP
1 - ADAPTER 6747-2A 2 - CUP 8115
3 - ADAPTER 6747-1A 4 - FIXTURE 6747(2) Install input shaft in fixture tool with Adapter Tool
6747-1A positioned under the shaft as shown (Fig. 82). (3) Install pilot bearing in input shaft (Fig. 82).
NOTE: The side of the pilot bearing with the small diameter goes toward the input shaft.
Fig.82PILOTBEARING&INPUTSHAFT
1 - PILOT BEARING 2 - INPUT SHAFT
Fig.83FOURTHGEARSYNCHRO
1 - FOURTH GEAR SYNCHRO RING 2 - INPUT SHAFT
(5) Adjust height of idler gear pedestal on fixture (Fig. 84). Start with a basic height of 18.4 cm (7-1/4
in.). Final adjustment can be made after gear is posi- tioned on pedestal.Fig.84IDLERPEDESTALBASEHEIGHT
1 - REVERSE IDLER PEDESTAL
21 - 28 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(6) Install assembled output shaft and geartrain in input shaft (Fig. 85). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
DR
Fig.86COUNTERSHAFTONFIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig.85OUTPUTSHAFT,GEARTRAIN&INPUT
SHAFT 1 - OUTPUT SHAFT AND GEARTRAIN 2 - INPUT SHAFT 3 - FIXTURE 6747
(7) Install Adapter 6747-2A on front bearing hub of if not previously done. The shoulder
countershaft, goes toward the countershaft.
(8) Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears before pro- ceeding (Fig. 86).
(9) Check alignment of countershaft and output shaft gear teeth. Gears may not align perfectly a dif- ference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This will not interfere with assembly. If difference is greater than this, the coun- tershaft adapter tool is probably upside down.
(10) Position reverse idler in support cup of fixture (Fig. 87). Verify idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out from the geartrain. Adjust pedestal up or down if necessary and verify short end of idler shaft is facing up as shown.
Fig.87REVERSEIDLERASSEMBLYONFIXTURE 1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT 3 - REVERSE IDLER ASSEMBLY 4 - PEDESTAL
DR MANUAL TRANSMISSION - NV3500 (Continued)
(11) On 2-wheel drive transmission, thread one Alignment Pin 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (Fig. 88).
MANUAL TRANSMISSION - NV3500
21 - 29
Fig.88ALIGNOUTPUTSHAFTBEARINGRETAINER 1 - ALIGNMENT PIN 2 - OUTPUT SHAFT BEARING RETAINER
(12) Assemble 1-2 and fifth reverse-shift forks (Fig. 89). Arm of fifth-reverse fork goes through slot in 1-2
fork.Fig.90SHIFTFORKSINSYNCHRO
1 - SYNCHRO SLEEVES 2 - FORK ARMS 3 - SHIFT FORKS
REAR HOUSING - 2WD
NOTE: Transmission shift components must be in Neutral position to prevent damaging the synchro and shift components when installing the housings.
(1) Drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface (Fig. 91).
Fig.891-2&FIFTH-REVERSESHIFTFORKS
1 - 1-2 FORK 2 - 1-2 FORK ARM 3 - FIFTH-REVERSE FORK
(13) Install assembled shift
in synchro sleeves and verify forks are seated in sleeves (Fig. 90).
forks
Fig.91REARHOUSINGDOWELS
1 - HOUSING ALIGNMENT DOWELS 2 - REAR HOUSING 3 - DOWEL FLUSH WITH SURFACE
21 - 30 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 92).
Fig.93COUNTERSHAFTBEARING
1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING
Fig.94REARHOUSING
1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN
(8) Seat rear housing on output shaft rear bearing and countershaft by tapping the housing with a plas- tic mallet.
Fig.92COUNTERSHAFTREARBEARING
1 - COUNTERSHAFT REAR BEARING 2 - REAR BEARING RACE 3 - REAR HOUSING 4 - PETROLEUM JELLY
NOTE: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 93).
(4) Apply extra petroleum jelly to hold counter- shaft rear bearing in place when housing is installed. (5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 93).
(6) Reach into countershaft rear bearing with fin- ger and push each bearing roller outward against the race. Then apply extra petroleum jelly to hold rollers in place during housing installation.
(7) Install rear housing onto geartrain (Fig. 94) and verify bearing retainer pilot stud is in correct bolt hole in housing. Verify countershaft and output shaft bearings are aligned in housing and on counter- shaft.
NOTE: It may be necessary to lift upward on coun- tershaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages the housing.
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 31
(9) Apply Mopar Gasket Maker or equivalent to housing bolt threads, bolt shanks and under bolt heads (Fig. 95).
ADAPTER HOUSING - 4WD
NOTE: Transmission shift components must be in Neutral to prevents damaging to the synchro and shift components when installing the housings.
(1) Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 97).
Fig.95HOUSINGBOLTS
1 - GASKET MAKER 2 - RETAINER AND HOUSING BOLTS 3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK AND THREADS
(10) Start first two bolts in retainer (Fig. 96). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 96).
(12) Tighten retainer bolts to 30-35 N·m (22-26 ft.
lbs.).
Fig.97ADAPTERHOUSING
1 - BEARING RETAINER 2 - RETAINER BOLT 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT BEARING RACE 5 - REAR BEARING
(3) Apply Mopar Gasket Maker or equivalent to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 95).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 93).
Fig.96AlitgnmentPinAndRetainerBolts
1 - BEARING RETAINER BOLT 2 - ALIGNMENT PIN
NOTE: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 93).
(6) Apply extra petroleum jelly to hold counter- shaft rear bearing in place when housing is installed. (7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 93).
21 - 32 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(8) Install adapter housing on geartrain. (9) Install rear bearing snap ring on output shaft
(Fig. 98).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET
(1) Verify all synchro sleeves are in Neutral posi-
tion (centered on hub).
CAUTION: Transmission synchros must all be in Neutral position to prevent damaging the housings, shift forks and gears while installing the housings.
(2) Install 3-4 shift fork in synchro sleeve (Fig. 100). Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.
Fig.98REARBEARINGSNAPRING
1 - SNAP RING PLIERS 2 - SNAP RING 3 - OUTPUT SHAFT
(10) Lubricate lip of new rear seal (Fig. 99) with
Mopar Door Ease, or transmission fluid.
(11) Install new rear seal in adapter housing bore with Installer C-3860-A. Verify seal is seated in hous- ing bore (Fig. 99).
Fig.1003-4SHIFTFORK
1 - 3-4 FORK 2 - ALIGN GROOVES IN FORK ARMS
(3) Slide shift shaft through 3-4 shift fork (Fig.
101).
Fig.99ADAPTERHOUSINGREARSEAL
1 - REAR SEAL 2 - SEAL LIP 3 - OUTPUT SHAFT
Fig.101SHIFTSHAFT
1 - SHIFT SHAFT 2 - 3-4 FORK 3 - SHAFT DETENT NOTCHES
DR MANUAL TRANSMISSION - NV3500 (Continued)
(4) Assemble shift shaft shift lever and bushing (Fig. 102). Verify slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.
MANUAL TRANSMISSION - NV3500
21 - 33
Fig.104SHAFTLEVEROPENING
1 - SHIFT SHAFT
Fig.102SHIFTSHAFTLEVERANDBUSHING
1 - SHAFT LEVER 2 - LEVER BUSHING 3 - BUSHING LOCK PIN SLOT
(5) Install assembled lever and bushing on shift
shaft (Fig. 103).
Fig.105SHIFTSOCKET
1 - SHIFT SOCKET 2 - SHIFT SHAFT
mission will have to be disassembled again to cor- rect shaft alignment.
(9) Select correct new roll pin for shift shaft lever (Fig. 106). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi- mately 33 mm (1-1/4 in.) long.Fig.106ROLLPINIDENTIFICATION
1 - SHAFT LEVER ROLL PIN 2 - SHIFT SOCKET ROLL PIN
Fig.103SHIFTSHAFTLEVERANDBUSHING
1 - SHIFT SHAFT 2 - SHAFT LEVER AND BUSHING 3 - 3-4 FORK
(6) Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (Fig. 104).
(7) Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 105).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Both shaft roll pins can be installed when the shaft is 180° off. If this occurs, the trans-
21 - 34 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(10) Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 107).
(13) Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 109).
Fig.107SHIFTSHAFTROLLPIN
Fig.109SHIFTSOCKETROLLPIN
1 - SHAFT LEVER ROLL PIN 2 - LEVER AND BUSHING
(11) Seat shaft lever roll pin with pin punch (Fig.
108).
CAUTION: Shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 108).
1 - ROLL PIN 2 - SHIFT SOCKET 3 - SHIFT SHAFT
(14) Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation (Fig. 110).
Fig.108SHIFTSHAFT/LEVERROLLPIN
1 - BUSHING LOCK PIN SLOT 2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig.110SEATSHIFTSOCKET
1 - PIN PUNCH 2 - SHIFT SOCKET 3 - SEAT ROLL PIN FLUSH 4 - SHIFT SOCKET
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 35
(15) Verify that notches in shift fork arms are
aligned (Fig. 111). Realign arms if necessary.
and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.
Fig.111SHIFTLEVERPOSITION
1 - SHIFT FORK ARMS 2 - DETENT BORE
(16) Rotate shift lever and bushing downward to
expose detent bore in the lever.
(17) Install detent spring then the ball into the detent bore (Fig. 112) and hold the ball in the lever. Then rotate the lever upward into the fork arm notches.
NOTE: Verify detent ball is seated in the fork arms before proceeding.
Fig.113INPUTSHAFT&COUNTERSHAFT
BEARING
1 - INPUT SHAFT BEARING 2 - COUNTERSHAFT FRONT BEARING 3 - SHIFT SHAFT BUSHING
(2) Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (Fig. 113). Large diameter side of bearing cage goes toward countershaft (Fig. 114). Small diameter side goes toward bearing race in housing.
(3) Reach into countershaft front bearing with fin- ger and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place during housing installation.
Fig.112DETENTSPRINGANDBALL
1 - SHAFT LEVER 2 - SPRING AND BALL 3 - MAGNET
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
(1) If previously removed, install input shaft bear- ing in front housing bore (Fig. 113). Install snap ring
Fig.114COUNTERSHAFTFRONTBEARING
1 - BEARING RACE 2 - PETROLEUM JELLY 3 - COUNTERSHAFT FRONT BEARING
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
21 - 36 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(5) Apply 1/8 in. wide bead of Mopar Gasket Maker or equivalent to mating surfaces of front and rear housings (Fig. 115).
DR
Fig.116HOUSINGBOLTS
1 - HOUSING BOLTS
(12) Install shift shaft bushing lock bolt (Fig. 117). Apply Mopar Gasket Maker or equivalent to bolt threads, shank and underside of bolt head before installation.
CAUTION: If lock bolt cannot be fully installed the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned.
Fig.115SEALHOUSINGS
1 - HOUSING FLANGE SURFACE 2 -GASKET MAKER
(6) Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.
CAUTION: Front housings will not seat if shift com- ponents are not in Neutral or one or more compo- nents are misaligned. Do not force the front housing into place.
(8) Tap rear housing alignment dowels back into place with hammer and pin punch. Both dowels should be flush fit in each housing. Have helper hold transmission upright while dowels are tapped back into place.
(9) Place transmission in horizontal position. (10) Apply Mopar Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 116).
(11) Install and start housing attaching bolts by hand (Fig. 116). Then tighten bolts to 34 N·m (25 ft. lbs.).
Fig.117SHAFTLOCKBOLT
1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET
shift
(13) Lubricate then install
shaft detent plunger in housing bore. Lubricate plunger with semi-synthetic/synthetic grease. Verify plunger is fully seated in detent notch in shift shaft. (14) Install detent spring inside plunger. (15) Install detent plug in end of Installer 8123. Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore. Drive detent plug into transmission case until plug seats.
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 37
(16) Install backup light switch (Fig. 118).
(19) Apply bead of Mopar silicone sealer or equiv- alent to flange surface of front bearing retainer (Fig. 121).
Fig.118BACKUPLIGHTSWITCH
1 - BACKUP LIGHT SWITCH
(17) Install input shaft snap ring (Fig. 119).
Fig.119SHAFTSNAPRING-TYPICAL
1 - INPUT SHAFT SNAP RING
(18) Install new oil seal in front bearing retainer
with Installer 6448 (Fig. 120).
Fig.121SEALBEARINGRETAINER-TYPICAL
1 - APPLY SEALER BEAD 2 - INPUT SHAFT BEARING RETAINER
(20) Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 122). Verify bolt holes are aligned before seating retainer.
CAUTION: Be sure sealer does not get into the oil feed hole in the transmission case or bearing retainer.
Fig.120BEARINGRETAINEROILSEAL
1 - INSTALLER 2 - FRONT BEARING RETAINER
Fig.122INPUTSHAFTBEARINGRETAINER
1 - INPUT SHAFT 2 - OIL FEED 3 - BEARING RETAINER
21 - 38 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(21) Install and tighten bearing retainer bolts to
7-10 N·m (5-7 ft. lbs.) (Fig. 123).
DR
Fig.123BEARINGRETAINERBOLTS-TYPICAL
1 - RETAINER BOLTS 2 - RETAINER
SHIFT TOWER AND LEVER
(1) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(2) Shift the transmission into third gear. (3) Align and install shift tower and lever assem- bly (Fig. 124). Be sure shift ball is seated in socket and the offset in the tower is toward the passenger side of the vehicle before installing tower bolts.
Fig.124SHIFTTOWER
1 - SHIFT TOWER 2 - SHAFT SOCKET 3 - SHIFT BALL
(4) Install shift tower bolts (Fig. 125) and tighten
bolts to 8.5 N·m (75.2 in. lbs.).
(5) Fill transmission to bottom edge of fill plug
hole with lubricant.
(6) Install and tighten fill plug to 34 N·m (25 ft.
lbs.).
Fig.125SHIFTTOWERBOLTS
1 - SHIFT TOWER AND LEVER ASSEMBLY
(7) Check transmission vent. Be sure vent is open
and not restricted.
INSTALLATION
NOTE: If a new transmission is being installed, use all components supplied with the new transmission. For example, if a new shift tower is supplied, do not re-use the original shift tower.
(1) Clean transmission front housing mounting
surface.
(2) Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces (Fig. 126) of following components:
† release fork ball stud. † release bearing slide surface. † input shaft splines. † release bearing bore. † propeller shaft slip yoke. (3) Support and secure transmission to jack. (4) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(5) Verify front housing is fully seated. Install transmission bolts without washers and tighten bolts into the engine to 41 N·m (30 ft. lbs.). Tighten the bolts with washers into the transmission to 68 N·m (50 ft. lbs.) (Fig. 127).
(6) Install rear crossmember and tighten nuts to
102 N·m (75 ft. lbs.).
(7) Install transmission rear mounting bolts and
tighten to 68 N·m (50 ft. lbs.). (8) Install front dust shield. (9) Install structural dust cover and tighten the
bolts to 73 N·m (54 ft. lbs.). (10) Install starter motor. (11) Install suspension crossmember and tighten
nuts to 102 N·m (75 ft. lbs.).
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 39
Fig.126LUBRICATIONPOINTS
Fig.127TRANSMISSION
1 - RELEASE FORK 2 - FORK BALL STUD 3 - BEARING SLIDE SURFACE 4 - SPLINE 5 - RELEASE BEAING
(12) Connect transmission harnesses to clips on
marks aligned.
case and connect switches.
(13) Install slave cylinder and tighten cylinder
nuts to 23 N·m (200 in. lbs.).
(14) Install transfer case and transfer case linkage
if equipped.
1 - BOLT WITHOUT WASHER 2 - BOLT WITH WASHER
(15) Remove transmission jack. (16) Install propeller shaft/shafts with reference
(17) Install exhaust on the exhaust manifolds. (18) Fill transmission with lubricant. Correct fill
level is to bottom edge of fill plug hole.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
Crossmember Nuts
Transmission Mount Bolts
4WD
Transmission Mount Bolts
2WD
Structural Dust Cover Bolts
Drain/Fill Plug
Front To Rear Housing Bolts Front Bearing Retainer Bolts
Idler Shaft Bolts
Rear Bearing Retainer Bolts
Shift Tower Bolts
Slave Cylinder Nuts Transfer Case Nuts
N·m 102
68
68
73
9-27
30-35
7-10
19-25
30-35
7-10
23
47Ft. Lbs.
In. Lbs.
75
50
50
54
14-20
22-26
5-7
14-18
22-26
5-7
17
3562-88
62-88
21 - 40 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued) SPECIAL TOOLSDR
REMOVERC-3985-B
INSTALLERC-3972-A
REMOVER6957
INSTALLER6951
HANDLEC-4171
REMOVER/INSTALLER6858
FIXTURE6747
ADAPTER6747-1A
ADAPTER6747-2A
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 41
CUP8115
ALIGNMENTSTUD8120
BEARINGSPLITTER1130
INSTALLERC-3860-A
TUBE6310-1
INSTALLER8123
INSTALLER8118
INSTALLER64428
REMOVER/INSTALLER8119
REMOVER8117A
21 - 42 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500
TABLE OF CONTENTS
page
DR
page
MANUAL TRANSMISSION - NV4500
ADAPTER HOUSING SEAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 44
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 79
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 79REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83SHIFT MECHANISM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85SHIFT COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86MANUAL TRANSMISSION - NV4500
DESCRIPTIONThe NV4500 is a five speed constant mesh manual transmission. All gear ranges including reverse are synchronized. Fifth gear is an overdrive range. The transmission has a cast iron gear case and aluminum shift cover.
Two versions are used, a standard duty for 5.7L applications and a heavy duty for V10 and Cummins diesel applications. Main difference is a larger diam- eter input shaft, for the heavy duty model.
Tapered roller bearings support the drive gear, mainshaft and countershaft in the gear case. Roller bearings in the drive gear support the forward end of the mainshaft. The mainshaft gears are all supported on caged type roller bearings. Drive gear thrust reac- tion is controlled by a needle type thrust bearing. The bearing is located at the forward end of the mainshaft.
The transmission is a top loader style. The shift lever is located in a shifter tower which is bolted to the shift cover and operates the shift forks and rails directly. The shift forks and rails are all located within the aluminum cover which is bolted to the top of the gear case.
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 1).
The tag provides the transmission model number, build date and part number. Be sure to reinstall the I.D. tag if removed during service. The information on the tag is essential to correct parts ordering.
Fig.1IDENTIFICATIONTAGLOCATION
1 - PTO COVER 2 - I.D. TAG
OPERATION
The manual transmission receives power through the clutch assembly from the engine. The clutch disc is splined to the transmission input shaft and is turned at engine speed at all times that the clutch is engaged. The input shaft is connected to the trans- mission countershaft through the mesh of fourth speed gear on the input shaft and the fourth counter- shaft gear. At this point all the transmission gears are spinning.
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
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noise, excessive wear, internal bind and hard shift- ing. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indi- cations of component damage are usually hard shift- ing and noise.
Component damage, incorrect clutch adjustment or damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Incorrect adjustment or a worn/damaged pressure plate or disc can cause incorrect release. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur- ing normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds. Severe highly audible transmission noise is generally the initial indicator of a lubricant problem. improper or contaminated lubricant will promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear breakage.
Insufficient,
REMOVAL
(1) Shift transmission into Neutral. (2) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(3) Remove shift lever extension from shift tower
and lever assembly.
(4) Remove shift tower bolts (Fig. 2).
The driver selects a particular gear by moving the shift lever to the desired gear position. This move- ment moves the internal transmission shift compo- nents to begin the shift sequence. As the shift lever moves the selected shift rail, the shift fork attached to that rail begins to move. The fork is positioned in a groove in the outer circumference of the synchro- nizer sleeve. As the shift fork moves the synchronizer sleeve, the synchronizer begins to speed-up or slow down the selected gear (depending on whether the driver is up-shifting or down-shifting). The synchro- nizer does this by having the synchronizer hub splined to the mainshaft, or the countershaft in some cases, and moving the blocker ring into contact with the gear’s friction cone. As the blocker ring and fric- tion cone come together, the gear speed is brought up or down to the speed of the synchronizer. As the two speeds match, the splines on the inside of the syn- chronizer sleeve become aligned with the teeth on the blocker ring and the friction cone and eventually will slide over the teeth, locking the gear to the mainshaft, or countershaft, through the synchronizer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or an incor- rect lubricant level check. A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a minute or so before checking. These recommendations will ensure an accurate check and avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition.
Leaks can occur at the mating surfaces of the gear case, adaptor or extension housing, or from the front/ rear seals. A suspected leak could also be the result of an overfill condition. Leaks at the rear of the extension or adapter housing will be from the hous- ing oil seals. Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening or use of a non-recommended sealer. A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may be seen drip- ping from the clutch housing after extended opera- tion. If the leak is severe, it may also contaminate the clutch disc causing the disc to slip, grab and or chatter.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant level, improper or contaminated lubricants. The con- sequence of using non-recommended lubricants is
1 - SHIFT TOWER 2 - SHIFTER 3 - BOLTS
