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Fig.2SHIFTTOWER
21 - 44 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(5) Remove shift tower and isolator plate from
transmission shift cover.
(6) Raise and support vehicle. (7) Remove skid plate, if equipped. (8) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(9) Remove exhaust system Y-pipe. (10) Disconnect speed sensor and backup light
switch connectors.
block.
(11) Support engine with safety stand and a wood
(12) If transmission is to be disassembled, remove drain bolt at bottom of PTO cover and drain lubri- cant (Fig. 3).
Fig.3FILLANDDRAINPLUGS
1 - PTO COVER 2 - DRAIN BOLT 3 - FILL PLUG
TWO WHEEL DRIVE
(1) Remove bolts attaching transmission to rear
crossmember mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmenber.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
Fig.4TRANSFERCASESHIFTER-TYPICAL
1 - TRANSMISSION 2 - TRANSFER CASE SHIFT MECHANISM
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts. (4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove
bolts/nuts
attaching
transmission
mount to rear crossmember.
(9) Remove rear crossmember bolts and pry out
crossmenber.
equipped.
(10) Remove clutch slave cylinder splash shield, if
(11) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
NOTE: The hydraulic linkage has a quick connect at the slave cylinder. This fitting should not be discon- nected.
NOTE: The hydraulic linkage has a quick connect at the slave cylinder. This fitting should not be discon- nected.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts. (7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans- fer case range lever. Then remove transfer case shift mechanism from transmission (Fig. 4).
(12) Remove transmission to clutch housing bolts. (13) Slide transmission and jack rearward until
input shaft clears clutch housing.
(14) Lower transmission jack and remove trans-
mission from under vehicle.
DISASSEMBLY
SHIFT MECHANISM
(1) Remove bolts holding shift tower to shift mech-
anism cover and remove tower.
DR MANUAL TRANSMISSION - NV4500 (Continued)
(2) Remove bolts (Fig. 5) holding shift mechanism
cover to transmission.
MANUAL TRANSMISSION - NV4500
21 - 45
Fig.7SHIFTMECHANISMCOVER
1 - SHIFT MECHANISM COVER 2 - ALIGNMENT DOWELS
Fig.5SHIFTMECHANISMCOVERBOLTS
EXTENSION/ADAPTER HOUSING
1 - SHIFT MECHANISM COVER 2 - BOLTS
(1) Remove bolts attaching extension/adapter hous-
ing to gear case (Fig. 8).
(3) Pry up shift mechanism cover at slot (Fig. 6) in
cover.
Fig.6LOOSENSHIFTMECHANISM
1 - SHIFT MECHANISM COVER SLOT 2 - PRY TOOL
(4) Raise mechanism up enough to disengage it
from the dowl pins (Fig. 7).
(5) Raise front of the mechanism and lift up and
off the transmission.
Fig.8EXTENSION/ADAPTERHOUSINGBOLTS
1 - EXTENSION HOUSING 2 - BOLTS (8)
21 - 46 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(2) Remove extension/adapter housing (Fig. 9). There is one alignment dowel in the gear case and one in the extension/adapter housing.
NOTE: Wedge breaker bar handle against workbench. Purpose of socket wrench and breaker bar is to pre- vent mainshaft from turning while nut is loosened.
(5) Remove fifth gear nut, then remove belleville
washer from mainshaft.
Fig.9EXTENSION/ADAPTERHOUSING
1 - GEAR CASE 2 - EXTENSION HOUSING
(3) Remove rubber spline seal from end of main- shaft (Fig. 10). The seal is used to prevent lubricant loss during shipping and does not have to be replaced if damaged.
Fig.10MAINSHAFTSPLINESEAL
1 - MAINSHAFT 2 - RUBBER SPLINE SEAL
FIFTH GEAR NUT
Fig.11FIFTHGEARNUT
1 - WRENCH 2 - FIFTH GEAR NUT 3 - SPLINE SOCKET
FIFTH GEAR
(1) Remove fifth gear shift fork roll pins (Fig. 12).
Drive roll pins out from the bottom of fork.
(1) Remove extension/adapter housing. (2) Loosen fifth gear clamp nut clamping screw
approximately 1 1/2 turns.
(3) Install Wrench 6743 on fifth gear nut (Fig. 11).
NOTE: Wrench only fits one way on nut. Make sure wrench is fully engaged in nut slots and is not cocked.
(4) Install Socket 6993 4X2 or Socket 6984 4X4 with breaker bar to hold mainshaft and remove fifth gear nut.
Fig.12FIFTHGEARSHIFTFORKROLLPINS
1 - ROLL PINS 2 - FIFTH GEAR SHIFT FORK
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 47
(2) Remove fifth gear clutch hub and gear snap
ring from countershaft (Fig. 13).
(3) Remove countershaft fifth gear clutch gear and
stop ring.
(4) Tap off fifth gear shift fork and gear assembly
off rail with plastic mallet.
(5) Remove fifth gear shift fork from sleeve. (6) Remove sleeve, struts and strut springs from
countershaft fifth gear hub, if necessary.
(8) Remove
coned shape
rear bearing thrust
washer from countershaft (Fig. 15).
NOTE: Note washer bore locating notch for assem- bly reference.
(9) Remove thrust washer locating pin from coun-
tershaft.
Fig.13FIFTHGEARCLUTCHGEARSNAPRING
1 - CLUTCH GEAR RING 2 - FIFTH SYNCHRO CLUTCH GEAR
(7) Remove countershaft fifth gear needle bearing
assembly (Fig. 14).
Fig.15COUNTERSHAFTREARBEARINGTHRUST
WASHER
1 - THRUST WASHER 2 - THRUST WASHER PIN
(10) Remove mainshaft fifth gear with Puller Set 6444 and Jaw 6459 or 6820. Position first Jaw on gear (Fig. 16).
Fig.14COUNTERSHAFTFIFTHGEARNEEDLE
BEARING
1 - NEEDLE BEARING 2 - COUNTERSHAFT
Fig.16JAWONMAINSHAFTFIFTHGEAR
1 - MAINSHAFT FIFTH GEAR 2 - JAW 3 - MAINSHAFT
21 - 48 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(11) Assemble Puller Flange 6444-1and Puller Rods 6444-3 4X2 or 6444-4 4X4 (Fig. 17). Slide assembly onto output shaft and seat flange in notch of jaw.
(13) Install Puller and Bolt 6444 on puller rods and secure puller to rods with retaining nuts (Fig. 19). Tighten puller bolt to remove gear from shaft splines.
Fig.17PULLERFLANGE
1 - JAW 2 - PULLER FLANGE
(12) Position second puller jaw on gear and in notch of puller flange (Fig. 18). Slide Collar 6444-8
over puller jaws to hold them in place.Fig.19PULLERASSEMBLY
1 - COLLAR 2 - JAWS 3 - BOLT 4 - WRENCH 5 - MAINSHAFT 6 - PULLER FLANGE
(14) Remove mainshaft rear bearing plate bolts and remove fifth gear plate end play shims and bear- ing cup (Fig. 20).
Fig.18PULLERCOLLAR
1 - JAWS 2 - COLLAR
Fig.20FIFTHGEARBEARINGPLATE,SHIMSAND
BEARINGCUP
1 - MAINSHAFT REAR BEARING CUP 2 - BEARING SHIMS 3 - BEARING PLATE 4 - FIFTH GEAR
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 49
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 21).
CAUTION: Do not reuse retainer bolts.
(4) Remove front retainer bearing cup with Puller 6444. Assemble Puller Flange 6444-1 and Puller Rods 6444-4 (Fig. 23). Insert Jaws 6453-1 in puller flange. Narrow lip of puller jaws will go under bearing cup.
Fig.21FRONTBEARINGRETAINER
1 - DRIVE GEAR 2 - FRONT BEARING RETAINER
(2) Lightly tap retainer back and forth with plastic
mallet to work it out of gear case.
NOTE: Retainer flange extends into transmission case and is a snug fit.
(3) Remove front retainer seal by (Fig. 22) collaps-
ing one side of seal then prying it out.
Fig.23PULLERRODS,FLANGEANDJAWS
1 - RODS 2 - FLANGE 3 - JAWS
(5) Install Disc C-4487-1 into bearing retainer for
Insert 6453-2 to rest upon.
(6) Install assembled tools in front retainer (Fig. 24) with puller jaws seated under bearing cup. Place Insert 6453-2 in center of puller jaws, to hold puller jaws in place.
Fig.22BEARINGRETAINERSEAL
1 - SEAL 2 - FRONT BEARING RETAINER
Fig.24INSERTANDRETAINER
1 - INSERT 2 - FRONT RETAINER 3 - JAWS
21 - 50 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(7) Install Puller 6444 on puller rods (Fig. 25) and install retaining nuts on puller rods. Tighten puller bolt to draw bearing cup out of retainer.
DR
Fig.26DRIVEGEAR
1 - MAINSHAFT 2 - DRIVE GEAR
Fig.25BEARINGCUPPULLERASSEMBLY
1 - WRENCH 2 - INSERT 3 - FRONT RETAINER 4 - PULLER 5 - WRENCH
DRIVE GEAR
(1) Remove drive gear (Fig. 26). (2) Remove pilot bearing from drive gear (Fig. 27). (3) Remove tapered bearing from drive gear with Puller Flange 6444-1 and Puller Rods 6444-6 (Fig. 28).
(4) Position first Jaw 6447 on bearing. Slide assembled puller flange and rod tools onto input shaft. Then seat flange in notch of puller jaw.
(5) Position second Jaw 6447 on gear and in notch of puller flange. Slide Collar 6444-8 over puller jaws to hold them in place.
(6) Install Puller 6444 on puller rods then install retaining nuts. Tighten puller bolt to remove bearing cone from drive gear.
MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral. (2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 29).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 30). (4) Roll gear case onto left side.
Fig.27PILOTBEARING
1 - DRIVE GEAR 2 - MAINSHAFT PILOT BEARING
(5) Remove mainshaft assembly (Fig. 31) by lifting front end of mainshaft slightly. Then grasp mainshaft rear splines and turn spline end of mainshaft coun- terclockwise to rotate shaft and geartrain out of case. Tilt mainshaft outward and removed from case.
NOTE: Handling mainshaft carefully because gears are lose on the mainshaft.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
32).
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 51
Fig.30FOURTHGEARCLUTCHGEARSTOPRING 1 - FOURTH GEAR SYNCHRO STOP RING 2 - FOURTH SPEED CLUTCH GEAR
Fig.28FRONTBEARINGPULLER
1 - PULLER 2 - RODS 3 - JAWS 4 - COLLAR 5 - FLANGE 6 - DRIVE GEAR
Fig.31MAINSHAFTANDGEARTRAIN
1 - MAINSHAFT AND CASE
Fig.29DRIVEGEARTHRUSTBEARING
1 - MAINSHAFT 2 - DRIVE GEAR THRUST BEARING
Fig.32COUNTERSHAFTREARBEARINGPLATE 1 - REAR BEARING PLATE 2 - COUNTERSHAFT
21 - 52 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33).
DR
Fig.33ENDPLAYSHIMANDREARBEARINGCUP 1 - COUNTERSHAFT REAR BEARING CUP 2 - END PLAY SHIM
(3) Remove reverse idler shaft (Fig. 34).
Fig.35IDLERGEARANDCOUNTERSHAFT
1 - REVERSE IDLER GEAR 2 - COUNTERSHAFT
Fig.36REVERSEIDLERGEAR
1 - REVERSE IDLER GEAR 2 - DRIVE GEAR BORE
Fig.37IDLERGEARCOMPONENTS
1 - BEARINGS 2 - REVERSE IDLER GEAR
Fig.34REVERSEIDLERSHAFT
1 - REVERSE IDLER SHAFT
(4) Rotate countershaft outward and push reverse idler gear away from countershaft and toward front of case (Fig. 35).
(5) Remove idler gear (Fig. 36). (6) Keep reverse idler gear bearings and spacer together (Fig. 37). Insert idler shaft through gear and bearings to keep them in place.
(7) Remove idler gear thrust washers from gear case. Install washers on idler shaft to keep them together for cleaning and inspection.
DR MANUAL TRANSMISSION - NV4500 (Continued)
(8) Remove countershaft rear bearing with Puller
Flange 6444-1 and Puller Rods 6444-4 (Fig. 38).
NOTE: Shaft cannot be removed from case until rear bearing has been removed.
MANUAL TRANSMISSION - NV4500
21 - 53
(9) Position first Jaw 6449 on bearing cone and
seat puller flange in notch of puller.
(10) Install second Jaw 6449 on bearing and in notch of puller flange. Slide Collar 6444-8 over puller jaws to hold them in place.
NOTE: Retaining collar has small and only fits one way over jaws.
lip on one end
(11) Install Puller 6444 on puller rods, then secure puller to rods with retaining nuts.Tighten puller bolt to remove bearing from shaft.
NOTE: If bearing is exceptionally tight, tap end of puller bolt with copper mallet to help loosen bear- ing.
Fig.39COUNTERSHAFTANDCASE
1 - COUNTERSHAFT
NOTE: Retaining collar has small and only fits one way over jaws.
lip on one end
(16) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts. Tighten puller bolt to remove bearing from shaft.NOTE: If bearing is exceptionally tight, tap end of puller bolt with mallet to help loosen bearing.
Fig.38COUNTERSHAFTREARBEARING
1 - COLLAR 2 - JAWS 3 - PULLER 4 - WRENCH
(12) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 39).
(13) Remove
front bearing, with Puller Flange 6444-1 and Puller Bolts 6444-4 (Fig. 40).
countershaft
(14) Position first Jaw 6451 on bearing and seat
puller flange in notch of puller jaw.
(15) Install second Jaw 6451 on bearing and in notch of puller flange. Slide Collar 6444-8 over puller jaws to hold them in place.
Fig.40CountershaftFrontBearing
1 - JAWS 2 - COLLAR 3 - PULLER 4 - FLANGE
(17) Remove bearing puller tools.
21 - 54 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 41).
DR
Fig.41COUNTERSHAFTFRONTBEARINGCAP
1 - HAMMER 2 - BEARING CAP
(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 42).
Fig.42COUNTERSHAFTFRONTBEARINGCUP
1 - REMOVER 2 - HANDLE
(3) Remove roll pin that secures shift lug on shift rail in case (Fig. 43). A small pin punch can be mod- ified by putting a slight bend in it to drive pin com- pletely out of shift rail (Fig. 43).
(4) Remove shift lug rail.
Fig.43SHIFTLUGROLLPIN
1 - PUNCH 2 - 30° BEND 3 - PIN PUNCH MODIFICATION 4 - SHIFT LUG 5 - SHIFT RAIL
MAINSHAFT
NOTE: Gear and synchro components can be installed backwards. Paint or scribe gear and syn- chro components for installation reference. Then stack geartrain parts in order of removal.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Place 3-4 gear in a press with support under 3rd gear and Remove 3-4 synchro hub, third gear stop ring and third gear as an assembly (Fig. 44).
(3) Remove third gear bearing from mainshaft
(Fig. 45).
(4) Remove third gear bearing spacer (Fig. 46). (5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 46).
(6) Remove second gear thrust washer (Fig. 47).
Note washer notch for locating pin.
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 55
Fig.46SNAPRINGANDTHIRDGEARBEARING
SPACER 1 - SECOND GEAR THRUST WASHER 2 - THRUST WASHER SNAP RING 3 - THIRD GEAR BEARING SPACER
Fig.47SECONDGEARTHRUSTWASHER
1 - SECOND GEAR 2 - THRUST WASHER 3 - SECOND GEAR BEARING
Fig.44THIRDGEAR,STOPRING,AND3-4HUB
1 - THIRD GEAR 2 - THIRD GEAR STOP RING 3 - 3-4 SYNCHRO HUB
Fig.45THIRDGEARBEARING
1 - THIRD GEAR NEEDLE BEARING
21 - 56 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(7) Remove thrust washer locating pin (Fig. 48)
with needle nose pliers.
(9) Remove second gear bearing (Fig. 50).
Fig.48THRUSTWASHERLOCATINGPIN
1 - THRUST WASHER LOCATING PIN
(8) Remove second gear (Fig. 49).
Fig.50SECONDGEARBEARING
1 - SECOND GEAR NEEDLE BEARING
(10) Remove second gear clutch cone snap ring
from mainshaft synchro hub groove (Fig. 51).
Fig.49SECONDGEAR
1 - SECOND GEAR
Fig.51SECONDGEARCLUTCHCONESNAPRING 1 - 1-2 SLEEVE 2 - SNAP RING 3 - SECOND GEAR CLUTCH CONE
DR MANUAL TRANSMISSION - NV4500 (Continued)
(11) Remove second gear clutch cone, synchro
clutch ring and synchro stop ring (Fig. 52).
MANUAL TRANSMISSION - NV4500
21 - 57
Fig.541-2SYNCHROSLEEVEANDHUB
1 - 1-2 SLEEVE AND HUB
Fig.52SECONDGEARCLUTCHCONEANDRING 1 - 1-2 SLEEVE AND HUB 2 - SYNCHRO STOP RING 3 - CLUTCH RING 4 - SECOND GEAR CLUTCH CONE
(12) Remove 1-2 synchro hub snap ring (Fig. 53).
Fig.531-2SLEEVEANDHUBSNAPRING
1 - 1-2 HUB SNAP RING 2 - 1-2 SLEEVE AND HUB
(13) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 54).
NOTE: Tapered side of sleeve also goes toward front. Do not disassemble synchro components unless worn or damaged.
(14) Remove first gear synchro stop ring and
clutch ring (Fig. 55).
(15) Remove first gear clutch cone front snap ring
from mainshaft hub (Fig. 56).
Fig.55FIRSTGEARSTOPANDCLUTCHRING
1 - FIRST GEAR CLUTCH RING 2 - FIRST GEAR STOP RING
Fig.56FIRSTGEARCLUTCHGEARFRONTSNAP
RING
1 - FIRST SPEED CLUTCH GEAR 2 - CLUTCH GEAR SNAP RING (FRONT)
21 - 58 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(16) Remove first gear clutch cone (Fig. 57). (17) Remove first gear clutch gear rear snap ring
from mainshaft hub (Fig. 57).
NOTE: Do not remove this snap ring unless main- shaft is being replaced.
DR
(18) Remove mainshaft rear bearing, with Puller Flange 6444-1 and Puller Rods 6444-3 for 4X2 or 6444-4 for 4X4.
(19) Position the first Jaw 6445 on the bearing cone and seat Puller Flange 6444-1 in notch of jaw (Fig. 58).
(20) Install second Jaw 6445 on the bearing cone and puller flange. Slide Collar 6444-8 over jaws to hold them in place.
Fig.57FIRSTGEARCLUTCHGEAR
1 - CLUTCH GEAR SNAP RING (REAR) 2 - FIRST SPEED CLUTCH GEAR
1 - REAR BEARING 2 - FLANGE 3 - JAW 4 - COLLAR
Fig.58MAINSHAFTREARBEARINGPULLER
5 - MAINSHAFT 6 - PULLER 7 - RODS 8 - JAW
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 59
(21) Install Puller 6444 on the puller rods and secure with nuts (Fig. 59). Tighten puller bolt to the remove bearing.
(22) Remove bearing puller tools and rear main-
shaft bearing from output shaft.
CAUTION: Do not disassemble synchro compo- nents unless they are damaged. If synchro sleeve or struts require service, mark position of sleeve on hub before removal. Correct sleeve position is important as sleeve can be installed backwards causing shift problems.
(25) Remove reverse gear bearing assembly from
mainshaft (Fig. 61).
Fig.59MAINSHAFTREARBEARING
Fig.61REVERSEGEAR,BEARING,ANDSTOP
RING
1 - JAWS 2 - COLLAR 3 - FLANGE 4 - MAINSHAFT 5 - PULLER 6 - TIGHTENING WRENCH 7 - HOLDING WRENCH 8 - RODS
(23) Remove reverse gear thrust washer (Fig. 60).
1 - FIRST GEAR 2 - REVERSE GEAR ASSEMBLY 3 - BEARING ASSEMBLY 4 - STOP RING
(26) Remove reverse gear bearing spacer from
mainshaft (Fig. 62).
(27) Remove reverse clutch gear snap ring (Fig. 62). Heavy duty snap ring pliers will be required to spread the ring far enough to remove it.
Fig.60REVERSEGEARTHRUSTWASHER
1 - REVERSE GEAR 2 - THRUST WASHER
(24) Remove reverse gear and synchro components
as assembly (Fig. 61).
Fig.62REVERSEGEARBEARINGSPACERAND
FIRSTGEARSNAPRING
1 - CLUTCH GEAR SNAP RING 2 - REVERSE GEAR BEARING SPACER
21 - 60 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(28) Remove reverse clutch gear (Fig. 63).
DR
Fig.63ReverseClutchGear
1 - REVERSE CLUTCH GEAR
(29) Remove first gear from bearing and mainshaft
(Fig. 64).
Fig.64FIRSTGEAR
1 - FIRST GEAR
(30) Remove first gear bearing from mainshaft
(Fig. 65).
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.
Fig.65FIRSTGEARBEARING
1 - MAINSHAFT 2 - FIRST GEAR BEARING
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and polished out with crocus cloth.
Inspect the reverse idler gear, bearings, shaft and thrust washers. Replace the bearings if the rollers are worn, chipped, cracked, flat-spotted or brinnelled. Replace the gear if the teeth are chipped, cracked or worn thin.
Inspect the front bearing retainer and bearing cup. Replace the bearing cup if scored, cracked, brinnelled or rough. Check the release bearing slide surface of the retainer carefully. Replace the retainer if worn or damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap ring grooves and threads. Replace the shaft if any surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the shaft if any surfaces exhibit considerable wear or damage.
Inspect shift forks for wear and distortion. Check fit of the sleeve in the fork to be sure the two parts fit and work smoothly. Replace the fork if the roll pin holes are worn oversize or damaged. Do not attempt to salvage a worn fork. Replace shift fork roll pins if necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots, pitting or other damage. Replace the bearings if nec- essary.
Inspect the blocker rings and fiction cones. replace either part if worn or damaged in any way. Replace if the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins. Replace the pins if bent or worn. Replace the wash- ers if worn or the locating pin notches are distorted. Inspect the case and housing/adapter sealing and mating surfaces are free of burrs and nicks. Inspcet
MANUAL TRANSMISSION - NV4500
21 - 61
DR MANUAL TRANSMISSION - NV4500 (Continued)
the alignment dowels in the case top surface and in the housing/adapter are tight and in good condition. Replace the gear case or housing/adapter if cracked or broken.
ASSEMBLY
NOTE: Gaskets are not used in the transmission. Use Mopar Silicone Sealer or equivalent on all gear case and extension housing sealing surfaces.
COUNTERSHAFT AND REVERSE IDLER GEAR
(1) Install countershaft front bearing cup in case
with Handle C-4171 and Installer 6061-1.
(2) Install
front bearing on countershaft with
Installer C-4340 (Fig. 66).
Fig.67COUNTERSHAFTINGEARCASE
1 - GEAR CASE 2 - COUNTERSHAFT
(6) Lubricate reverse idler gear bearings with petroleum jelly and install first bearing and second bearing (Fig. 68).
(7) Install idler gear front thrust washer on boss in gear case (Fig. 68). Coat thrust washer with lib- eral quantity of petroleum jelly to hold it in place.
Fig.66COUNTERSHAFTFRONTBEARING
1 - FRONT BEARING 2 - INSTALLER 3 - COUNTERSHAFT
(3) Lubricate countershaft front bearing cup and
cone with petroleum jelly.
(4) Position gear case on end with rear of case fac-
ing up (Fig. 67).
(5) Install countershaft in gear case (Fig. 67).
NOTE: Do not install rear countershaft bearing on countershaft at this time.
Fig.68IDLERGEARFRONTTHRUSTWASHER
1 - IDLER GEAR FRONT THRUST WASHER ON BOSS
21 - 62 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(8) Install reverse idler gear in case (Fig. 69). (9) Install idler gear rear thrust washer between
idler gear and case boss (Fig. 69).
DR
Fig.69IDLERGEAR
1 - REAR THRUST WASHER 2 - REVERSE IDLER GEAR 3 - FRONT THRUST WASHER
(10) Align idler gear bearings and thrust washers
with a drift.
(11) Install reverse idler shaft with notched end of
shaft facing countershaft (Fig. 70).
Fig.70REVERSEIDLERSHAFT
1 - COUNTERSHAFT 2 - SHAFT NOTCH 3 - REVERSE IDLER SHAFT
(12) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 71).
(13) Install rear bearing cone on countershaft with
Installer C-4040 (Fig. 72).
(14) Remove wood block from under countershaft and lower countershaft front bearing into front bear- ing cup.
Fig.71SUPPORTINGCOUNTERSHAFT
1 - COUNTERSHAFT 2 - WOOD BLOCK
Fig.72COUNTERSHAFTREARBEARING
1 - INSTALLER 2 - REAR BEARING 3 - COUNTERSHAFT
(15) Lubricate countershaft rear bearing cup and
cone with petroleum jelly.
(16) Install countershaft rear bearing cup in gear case and over rear bearing (Fig. 73). Tap cup into place with plastic mallet if necessary.
(17) Install countershaft rear bearing plate (Fig.
74).
NOTE: Verify plate is seated in notch in reverse idler shaft before tightening bearing plate bolts.
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 63
Fig.73COUNTERSHAFTREARBEARINGCUP
1 - COUNTERSHAFT REAR BEARING CUP
Fig.75COUNTERSHAFTFRONTBEARINGCAP
1 - FRONT BEARING CAP
Fig.74COUNTERSHAFTREARBEARINGPLATE 1 - COUNTERSHAFT 2 - REAR BEARING PLATE 3 - IDLER SHAFT
(18) Apply Mopar silicone adhesive/sealer or equiv- alent to flange and lip of new cap. Install new front bearing cap in gear case (Fig. 75) with Handle C-4171 and Installer C-3972-A.
COUNTERSHAFT END PLAY
Fig.76MEASURINGCOUNTERSHAFTENDPLAY 1 - DIAL INDICATOR 2 - COUNTER SHAFT 3 - INDICATOR MOUNTING ARM AND BASE
(1) Rotate countershaft 4-5 times to seat bearings. (2) Mount dial indicator on case. Then position indicator plunger on end of countershaft and zero dial indicator (Fig. 76).
(3) Raise countershaft with screwdriver and note end play reading on dial indicator. End play should be 0.051 - 0.15 mm (0.002 - 0.006 in.).
(4) Remove countershaft rear bearing plate. (5) Install a end play shim that will provide mini- mum countershaft end play. Position shim on rear bearing cup (Fig. 77).
Fig.77COUNTERSHAFTENDPLAYSHIM
1 - REAR BEARING CUP 2 - END PLAY SHIM (SELECTIVE)
21 - 64 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
NOTE: Four of these snap rings are used to secure various components on the mainshaft 1-2 synchro hub. The snap rings are all the same size and are interchangeable.
(6) Install countershaft rear bearing plate (Fig.
74).
NOTE: Verify plate is seated in reverse idler shaft notch and end play shims are still in position before installing bolts.
(7) Apply 1-2 drops Mopar Loc N’ Seal or equiva- lent to threads of rear bearing plate bolts. Then install and tighten bearing plate bolts to 23 N·m (200
in. lbs.).SHIFT LUG AND RAIL
(1) Lubricate shift lug and rail with Castrolt Syn-
torq or equivalent.
(2) Insert shift lug rail part way into case. (3) Install shift lug on rail. (4) Position shift rail so roll pin notches are
toward outside of case (Fig. 78).
(5) Install roll pin that secures lug to rail (Fig. 78).
Fig.79FIRSTGEARBEARINGANDSNAPRING
1 - SNAP RING 2 - FIRST GEAR BEARING 3 - MAINSHAFT SYNCHRO HUB
(2) Install first gear clutch cone on mainshaft 1-2
synchro hub with recessed side of cone facing front (Fig. 80). Verify cone is seated against snap ring on hub.Fig.78SHIFTLUGANDRAIL
1 - NOTCHES (FOR 5TH GEAR SHIFT FORK ROLL PINS) 2 - LUG RAIL 3 - ROLL PIN HOLE 4 - SHIFT LUG
MAINSHAFT AND GEARTRAIN
CAUTION: The reverse, 1-2 and 3-4 synchro compo- nents can be assembled and installed incorrectly. Follow assembly procedures for component identi- fication and location.
Lubricate mainshaft bearing surfaces and all bear- ing assemblies with Castrolt Syntorq or with petro- leum jelly.
(1) Install first snap ring in rear most groove of mainshaft hub (Fig. 79). This snap ring locates first gear clutch gear on shaft.
Fig.80FIRSTGEARCLUTCHCONE
1 - MAINSHAFT 1-2 SYNCHRO HUB 2 - FIRST GEAR CLUTCH CONE
DR MANUAL TRANSMISSION - NV4500 (Continued)
(3) Install snap ring on mainshaft 1-2 synchro hub to secure clutch cone (Fig. 81). Verify snap ring is seated in hub groove and against clutch cone.
MANUAL TRANSMISSION - NV4500
21 - 65
Fig.821-2SYNCHROSLEEVEONHUB
1 - ALIGN WIDE SLOT IN SLEEVE WITH WIDE SPLINE OF HUB 2 - 1-2 SLEEVE AND HUB
Fig.81FIRSTGEARCLUTCHCONESNAPRING
1 - FIRST GEAR CLUTCH CONE 2 - MAINSHAFT 1-2 SYNCHRO HUB 3 - CLUTCH CONE SNAP RING
(4) Support mainshaft in upright position to install remaining gears, snap rings and synchro compo- nents. Shaft can be supported in gear case or hole can be cut in workbench to support shaft.
(5) If 1-2 synchro hub and sleeve were disassem- bled for service, reassemble hub, sleeve, struts and springs as follows:
(a) Align and install sleeve on hub. Rotate sleeve until it slides onto hub. Sleeve only fits one way and will easily slide onto hub when long slot in sleeve, aligns with long shoulder on hub (Fig. 82). (b) Place wood blocks under hub that will raise hub about 3.5 cm (1.375 in.) above surface of work- bench. Then allow sleeve to drop down on hub (Fig. 83).
(c) Install springs and struts in hub (Fig. 83). Use lots of petroleum jelly to hold them in place. Then compress struts with your fingers and move sleeve upward until struts are started in sleeve. Verify that struts are engaged in sleeve before pro- ceeding.
(d) Turn synchro assembly upright. Then move sleeve into neutral position on hub and work struts into sleeve at same time. Be sure struts are seated and springs are not displaced during assembly.
Fig.831-2SYNCHROSTRUTSANDSPRINGS
1 - WOOD BLOCKS 2 - HUB 3 - SLEEVE 4 - STRUTS AND SPRINGS (4 EACH)
21 - 66 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(6) Install first gear stop ring in 1-2 synchro hub and sleeve (Fig. 84). Verify stop ring is seated and engaged in hub and sleeve.
(8) Install snap ring that secures 1-2 synchro on mainshaft hub (Fig. 86). Verify snap ring is seated in groove in mainshaft hub.
Fig.84FIRSTGEARSTOPRINGINSYNCHROHUB (7) Install 1-2 synchro assembly and stop ring on mainshaft with the taper on the sleeve facing for- ward. (Fig. 85).
Fig.861-2SYNCHROSNAPRING
1 - SYNCHRO SNAP RING 2 - 1-2 SYNCHRO ASSEMBLY 3 - MAINSHAFT HUB
(9) Assemble second gear clutch cone, clutch ring
and stop ring (Fig. 87).
Fig.851-2SYNCHRO
1 - MAINSHAFT HUB 2 - 1-2 SYNCHRO ASSEMBLY 3 - TAPERED SIDE OF SLEEVE
Fig.87SECONDGEARCLUTCHCONE,CLUTCH
RINGANDSTOPRING
1 - STOP RING 2 - CLUTCH RING 3 - CLUTCH CONE
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 67
(10) Install assembled second gear clutch cone and rings on mainshaft and in 1-2 synchro hub (Fig. 88).
(12) Install second gear bearing on mainshaft (Fig.
90).
Fig.88SECONDGEARCLUTCHCONE,CLUTCH
Fig.90SECONDGEARBEARING
RINGANDSTOPRING
1 - SECOND GEAR BEARING
1 - CLUTCH CONE 2 - STOP RING 3 - CLUTCH RING
(11) Install snap ring that secures second gear clutch cone on mainshaft (Fig. 89). Use narrow blade screwdriver to work snap ring into hub groove as shown. Verify snap ring is seated in mainshaft groove.
NOTE: If snap ring will not fit in groove, clutch cone is slightly misaligned.
(13) Install second gear on mainshaft and bearing. Rotate gear until tabs of second gear clutch ring are seated in tab slots in gear (Fig. 91).
Fig.91SECONDGEAR
1 - SECOND GEAR 2 - CLUTCH RING TABS 3 - TAB SLOTS (IN GEAR)
Fig.89SECONDGEARCLUTCHCONESNAPRING 1 - SCREWDRIVER 2 - MAINSHAFT HUB 3 - SNAP RING 4 - SECOND GEAR CLUTCH CONE
21 - 68 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(14) Install thrust washer pin in shaft (Fig. 92).
DR
Fig.92THRUSTWASHERPIN
1 - THRUST WASHER PIN 2 - SECOND GEAR
(15) Install second gear
thrust washer. Verify
washer is seated on gear and pin (Fig. 93).
Fig.94SNAPRINGANDTHIRD
1 - SECOND GEAR THRUST WASHER 2 - THRUST WASHER SNAP RING 3 - THIRD GEAR BEARING SPACER
Fig.93SECONDGEARTHRUSTWASHER
1 - THIRD GEAR BEARING
Fig.95THIRDGEARBEARING
1 - SECOND GEAR 2 - SECOND GEAR THRUST WASHER 3 - LOCATING PIN IN WASHER NOTCH
(16) Install second gear thrust washer snap ring (Fig. 94). Verify snap ring is seated in mainshaft groove.
(17) Install third gear bearing spacer on shaft and
seat it against thrust washer snap ring (Fig. 94).
(18) Install third gear bearing on mainshaft (Fig.
95). Bearing should be flush with mainshaft hub.
NOTE: If bearing is not flush with hub, the bearing spacer or snap ring was not installed.
(19) Install third gear over bearing and onto main-
shaft (Fig. 96).
Fig.96THIRDGEAR
1 - THIRD GEAR
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 69
(20) Install synchro stop ring on third gear (Fig.
97). Verify stop ring is seated on cone taper.
(22) Start 3-4 synchro assembly on mainshaft with the hub groove and sleeve groove both facing for- ward. Tap assembly onto shaft splines until hub is about 3 mm (0.125 in.) away from third gear stop ring. Then align stop ring with synchro sleeve and hub and seat synchro assembly with Installer C-4040
(Fig. 99).Fig.97THIRDGEARSTOPRING
1 - SYNCHRO STOP RING 2 - THIRD GEAR
(21) If 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align and install synchro sleeve on hub (Fig. 98). Front side of hub has a narrow groove machined in it. (b) Insert all
three synchro struts
in slots
machined in sleeve and hub (Fig. 98).
(c) Install and seat synchro springs (Fig. 98). Use screwdriver to compress springs and seat them in struts and hub as shown.
Fig.98SYNCHROASSEMBLY(3-4)
1 - STRUT (3) 2 - SPRING (3) 3 - 3-4 SLEEVE 4 - 3-4 HUB
Fig.99SEATING3-4SYNCHROASSEMBLYON
MAINSHAFT
1 - 3-4 SYNCHRO HUB 2 - HUB GROOVE 3 - INSTALLER C-4040
(23) Verify 3-4 synchro hub is seated on shaft with approximately 3 mm (0.125 in.) of shaft spline visi- ble.
NOTE: If hub is not seated, stop ring lugs are mis- aligned. Rotate ring until lugs are engaged in 3-4
hub slots.(24) Verify that second and third gear rotate freely at this point. If not, determine the cause and correct.
(25) Invert mainshaft in case or bench. (26) Install first gear bearing on mainshaft. (27) Install first gear on shaft with clutch hub side of gear facing the front of shaft (Fig. 100). Verify tabs on clutch ring are aligned and seated in first gear hub.
NOTE: 1-2 synchro hub will not seat properly if clutch ring tabs are misaligned.
21 - 70 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(28) Install reverse clutch gear on first gear (Fig.
100). Verify clutch gear is seated on shaft splines.
(29) Install reverse clutch gear snap ring with heavy duty snap ring pliers (Fig. 100). Verify snap ring is seated in groove.
NOTE: Reverse gear will not fit properly if snap ring is not seated.
Fig.102REVERSEGEARBEARINGANDSPACER 1 - REVERSE GEAR BEARING 2 - BEARING SPACER 3 - FIRST GEAR
CAUTION: The reverse sleeve will fit either way on the hub. Verify tapered side of the sleeve faces rearward.
Fig.100FIRSTGEARANDCLUTCHGEAR
1 - FIRST GEAR 2 - REVERSE CLUTCH GEAR SNAP RING 3 - REVERSE CLUTCH GEAR
(30) Install stop ring on clutch cone (Fig. 101). Ver-
ify stop ring is seated on cone taper.
Fig.101CLUTCHGEARSTOPRING
1 - REVERSE GEAR STOP RING 2 - CLUTCH GEAR 3 - FIRST GEAR
(31) Install reverse gear bearing spacer on main- shaft and seat against reverse clutch gear snap ring (Fig. 102).
(32) Install reverse gear bearing on mainshaft
(Fig. 102).
(33) If reverse gear sleeve and struts were disas- sembled for service, reassemble sleeve, struts and springs as follows:
(a) Position sleeve on hub so tapered side of
sleeve faces rearward. (Fig. 103).
(b) Rotate sleeve to align teeth on sleeve and hub. Sleeve will slide easily into place on hub when properly aligned.
(c) Install springs in gear hub (Fig. 103). Use petroleum jelly to hold springs in place if desired. (d) Compress first spring with flat blade screw- driver and slide strut into position in hub slot. Then work spring into seat in strut with small hooked tool or screwdriver.
Fig.103REVERSEGEARSYNCHROASSEMBLY
1 - REVERSE GEAR 2 - SLEEVE 3 - SPRING (3) 4 - STRUT (3) 5 - HUB
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 71
(e) Install second and third struts in same man-
ner as described in step (d).
(f) Work sleeve upward on hub until struts are centered and seated in sleeve. Sleeve should be in neutral position after seating struts. (34) Install reverse gear and synchro assembly on mainshaft (Fig. 104). Rotate assembly until stop ring lugs engage in hub slots and gear drops into seated position.
Fig.106MAINSHAFTREARBEARING
1 - INSTALLER 2 - MAINSHAFT REAR BEARING
Fig.104REVERSEGEAR 1 - REVERSE GEAR AND SYNCHRO ASSEMBLY
(35) Install reverse gear thrust washer (Fig. 105).
Fig.107FOURTHGEARSTOPRING
1 - 3-4 SYNCHRO SLEEVE 2 - FOURTH SPEED STOP RING
Fig.105REVERSEGEARTHRUSTWASHER
1 - THRUST WASHER 2 - REVERSE GEAR
(36) Install
on mainshaft with Installer 6446. Seat bearing on output shaft and against thrust washer (Fig. 106).
rear bearing
(37) Install fourth gear stop ring in 3-4 synchro
(38) Install fourth gear clutch gear in stop ring
sleeve (Fig. 107).
(Fig. 108).
(39) Roll gear case onto its left side. (40) Grip mainshaft at pilot bearing hub and just behind reverse gear. Then lift assembly and guide rear of shaft through bearing bore at rear of case.
(41) Continue holding front of shaft but switch grip at rear to shaft output splines. Lift mainshaft assembly slightly, align gears and seat assembly in case.
Fig.108FOURTHGEARCLUTCHGEAR
1 - FOURTH SPEED CLUTCH GEAR
21 - 72 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(42) Set transmission case upright (Fig. 109).
DRIVE GEAR AND RETAINER
DR
(1) Install bearing on drive gear with Installer
6448 (Fig. 111).
Fig.111FRONTBEARINGONDRIVEGEAR
1 - INSTALLER 2 - BEARING 3 - DRIVE GEAR
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear rearward until mainshaft hub is seated in pilot bear- ing.
(4) Install bearing cup in front retainer with Han-
dle C-4171 and Installer C-4308 (Fig. 112).
Fig.109MAINSHAFTANDGEARTRAININCASE
1 - MAINSHAFT AND GEARTRAIN 2 - FOURTH SPEED CLUTCH GEAR
(43) Install drive gear thrust bearing on mainshaft (Fig. 110). Use plenty of petroleum jelly to hold bear- ing in place.
(44) Check alignment and mesh of mainshaft gears. If gears are not aligned, roll case on side and realign shaft and gears in case.
Fig.110DRIVEGEARTHRUSTBEARING
1 - MAINSHAFT 2 - DRIVE GEAR THRUST BEARING
Fig.112FRONTBEARINGCUPINRETAINER
1 - INSTALLER 2 - HANDLE 3 - WOOD BLOCKS 4 - RETAINER
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 73
(5) Install new oil seal in front bearing retainer with Installer 6052 (Fig. 113). Use one or two wood blocks to support retainer as shown. Lubricate seal lip with petroleum jelly after installation.
(10) Align front bearing retainer bolt holes and tap retainer into place with plastic mallet. Install new retainer bolts and tighten to 30 N·m (22 ft. lbs.) (Fig. 115).
NOTE: Never reuse the old bolts.
Fig.113BEARINGRETAINEROILSEAL
MAINSHAFT END PLAY
Fig.115FRONTBEARINGRETAINER
1 - DRIVE GEAR 2 - FRONT BEARING RETAINER
1 - INSTALLER 2 - RETAINER 3 - WOOD BLOCK
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover.
(7) Apply Mopar Silicone Sealer or equivalent to
flange surface of front bearing retainer (Fig. 114).
(8) Install front bearing retainer over drive gear
and start it into case.
(9) Start front bearing retainer in gear case. Verify (12
the top-center
is at
retainer O’clock) position (Fig. 114).
lube channel
Fig.114LOCATIONOFFRONTRETAINERLUBE
CHANNEL
1 - LUBE CHANNEL 2 - FRONT RETAINER 3 - APPLY GASKET MAKER HERE
(1) Install mainshaft rear bearing cup in case and over bearing. Tap bearing cup into place with plastic mallet.
(2) Install rear bearing plate to hold mainshaft
and rear bearing in position (Fig. 116).
NOTE: Do not install any end play shims at this time.
(3) Tighten rear bearing plate bolts securely. (4) Place gear case in upright position on bench. Either cut hole in bench to accept drive gear and front retainer or use C-clamps to secure transmission on bench.
NOTE: Do not leave transmission unsupported.
(5) Install Extension Rod 8161 into a suitable
threaded hole in rear of case.
(6) Mount dial indicator on extension rod and posi-
tion indicator plunger against end of mainshaft.
(7) Move mainshaft forward to remove all play
then zero dial indicator.
(8) Move mainshaft upward and record dial indica- tor reading. Move mainshaft with pry tool positioned between drive gear and case.
(9) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play. If end play adjustment is required, remove bearing plate and install necessary shim.(10) Reinstall rear bearing plate with oil hole in
bearing plate at the top (Fig. 116).
(11) Apply Mopar Lock N’ Seal or equivalent to bearing plate bolt threads. Install and tighten bolts to 23 N·m (200 in. lbs.).
21 - 74 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
Fig.118FIFTHGEARTHRUSTWASHERPIN
1 - THRUST WASHER PIN 2 - COUNTERSHAFT
Fig.116REARBEARINGPLATE
1 - BEARING PLATE OIL HOLE (AT TOP) 2 - MAINSHAFT REAR BEARING PLATE
(12) Install mainshaft
fifth gear with Installer 6446 (Fig. 117). Gear is seated when it contacts rear bearing.
Fig.119FIFTHGEARTHRUSTWASHER
1 - PIN 2 - THRUST WASHER
Fig.117MAINSHAFTFIFTHGEAR
1 - MAINSHAFT FIFTH GEAR 2 - INSTALLER
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) Install thrust washer pin in countershaft (Fig.
118).
(2) Install thrust washer on countershaft. Turn washer until pin engages in washer notch (Fig. 119).
NOTE: The flat side of washer faces the rear and cone side faces the front.
(3) Lubricate and install
countershaft (Fig. 120).
fifth gear bearing on
Fig.120COUNTERSHAFTFIFTHGEARBEARING 1 - COUNTERSHAFT 2 - FIFTH GEAR NEEDLE BEARING
DR MANUAL TRANSMISSION - NV4500 (Continued)
(4) Install synchro sleeve on hub of countershaft fifth gear with tapered side of sleeve facing front and the flat side facing rear (Fig. 121).
MANUAL TRANSMISSION - NV4500
21 - 75
Fig.121SYNCHROSLEEVEONCOUNTERSHAFT
FIFTH
1 - GEAR HUB 2 - SYNCHRO SLEEVE 3 - COUNTERSHAFT FIFTH GEAR
(5) Install shift fork in synchro sleeve (Fig. 122).
Fig.123COUNTERSHAFTFIFTHGEAR,SHIFT
FORKANDSYNCHROSLEEVE
1 - SHIFT FORK AND SLEEVE 2 - FIFTH GEAR HUB 3 - SHIFT FORK ROLL PINS
Fig.122FIFTHGEARSHIFTFORKINSYNCHRO
SLEEVE
1 - SYNCHRO SLEEVE 2 - SHIFT FORK
(6) Install assembled fifth gear, synchro sleeve and shift fork (Fig. 123). Align fork with shift lug rail and align gear with bearings and countershaft. Start components onto shaft and rail, then tap gear and fork into place with plastic or rawhide mallet.
(7) Install fifth gear synchro struts and springs
(Fig. 124).
Fig.124FIFTHGEARSYNCHROSTRUTSAND
SPRINGS
1 - FIFTH GEAR HUB 2 - SYNCHRO SPRING (3) 3 - SYNCHRO STRUT (3)
21 - 76 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(8) Assemble and install fifth synchro clutch gear and stop ring in fifth gear hub (Fig. 125). Verify parts are seated in fifth gear hub.
Fig.125FIFTHSYNCHROCLUTCHGEARAND
STOPRING
1 - STOP RING 2 - CLUTCH GEAR
(9) Install clutch gear snap ring (Fig. 126).
Fig.126FIFTHSYNCHROCLUTCHSNAPRING
1 - CLUTCH GEAR RING 2 - FIFTH SYNCHRO CLUTCH GEAR
(10) Align roll pin holes in shift fork with notches in shift lug rail. Then install roll pins from top side of fork (Fig. 123).
NOTE: Roll pins only fit one way due to small shoulder at one end of each pin.
FIFTH GEAR NUT
(1) Install belleville washer onto the mainshaft. (2) Install fifth gear nut over the mainshaft. (3) Tighten the clamp bolt until the gap in the
clamp nut assembly is closed.
(4) Back the clamp bolt off one full turn.
(5) Place 10-15 drops of Loctite 272 onto the main- threads where the fifth gear nut will be
shaft engaged.
(6) Install fifth gear nut on mainshaft (Fig. 127).
Fig.127FIFTHGEARNUT
1 - FIFTH GEAR 2 - FIFTH GEAR NUT
(7) Hold mainshaft Socket 6993 4X2 or Socket
6984 4X4 while installing the fifth gear nut.
(8) Tighten fifth gear nut as much as possible with Wrench 6743, long handle ratchet, breaker bar and applicable socket wrench (Fig. 128).
Fig.128FIFTHGEARNUT
1 - WRENCH 2 - FIFTH GEAR NUT 3 - SOCKET
(9) Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 77
(10) Tighten fifth gear nut with Nut Wrench 6743
and high capacity torque wrench. Tighten nut to 366- 380 N·m (270-280 ft. lbs.). Have helper hold trans- mission steady if necessary.(11) Torque the fifth gear clamp nut clamping bolt
to 13.5 N·m (10 ft. lbs.).
(12) Unlock the mainshaft gears by shifting all
synchro sleeves out of the engaged position.
EXTENSION/ADAPTER HOUSING
(1) Clean mating surfaces of extension/adapter housing and gear case with a wax and grease remover.
(2) Check alignment dowels in gear case and hous- ing or adapter. Be sure dowels are in position and seated.
(3) Apply Mopar Silicone Sealer or equivalent to
gear case and housing mating surfaces.
(4) Align and install extension/adapter housing on
gear case (Fig. 129).
Fig.129INSTALLINGEXTENSION/ADAPTER
HOUSING
1 - GEAR CASE 2 - EXTENSION HOUSING
(5) Apply Mopar Lock N’ Seal or equivalent to
threads of extension/adapter housing bolts.
(6) Install and tighten housing bolts to 54 N·m (40
ft. lbs.).
SHIFT MECHANISM
(1) Clean mating surfaces of shift cover and gear
case with wax and grease remover.
(2) Apply a small amount of Mopar silicone sealer
or equivalent to sealing surface of shift cover.
CAUTION: Do not over-apply an excesive amount sealer. Excess can squeezed into gear case and could block lubricant feed holes in time.
(3) Lubricate synchro sleeves with Castrolt Syn- torq gear lubricant or equivalent. Then apply light coat of petroleum jelly to shift fork contact surfaces.
(4) Verify shift fork pads (Fig. 130) are secure.
Fig.130SHIFTFORKPAD
1 - SHIFT FORK PADS 2 - FIFTH-REVERSE FORK
(5) Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
(6) Align and seat shift cover on transmission.
NOTE: If cover will not seat, it may not be aligned on gear case dowels or shift forks are not aligned with sleeves and shift lug.
(7) Apply Mopar Lock N’ Seal or equivalent to
threads of shift cover bolts.
(8) Install shift cover bolts and tighten to 27-31
N·m (216-276 in. lbs.).
(9) Apply sealer to backup lamp switch. Install switch into cover and tighten to 22-34 N·m (193-265
in. lbs.).(10) Install vent assembly if removed. Apply an adhesive/sealer to vent tube to help secure it in cover.
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 with the new transmission, do not re-use the original shift tower.
(1) Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of the following components: † input shaft splines. † release bearing slide surface of front retainer. † release bearing bore. † release fork.
DR
FOUR WHEEL DRIVE
(1) Install transfer case shift mechanism on trans-
(2) Install
transfer case on transmission jack.
Secure transfer case to jack with safety chains.
(3) Raise jack and align transfer case input gear
with transmission mainshaft.
(4) Move transfer case forward and seat it on
adapter.
(5) Install transfer case nuts and tighten to: † If 3/8 studs 41-47 N·m (30-35 ft. lbs.). † If 5/16 studs 30-41 N·m (22-30 ft. lbs.). (6) Install transfer case shift mechanism to side of
transfer case.
on transfer case.
(7) Connect transfer case shift lever to range lever
(8) Align and connect propeller shafts. (9) Fill
transmission with required lubricant. Check lubricant level in transfer case and add lubri- cant if necessary.
(10) Install transfer case skid plate, if equipped and crossmember. Tighten attaching bolts/nuts to 41
N·m (30 ft. lbs.).(11) Install exhaust system components. (12) Lower vehicle. (13) Clean the mating surfaces of shift tower, iso- lator plate and shift cover with suitable wax and grease remover.
(14) Apply Mopar Gasket Maker or equivalent to the sealing surface of the shift cover. Do not over apply sealant.
(15) Install the isolator plate onto the shift cover,
metal side down.
(16) Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and the isolator plate.
(17) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(18) Install the bolts to hold the shift tower to the isolator plate and the shift cover. Tighten the shift tower bolts to 10.2-11.25 N·m (7.5-8.3 ft. lbs.).
(19) Install the shift lever extension onto the shift
tower and lever assembly.
(20) Install shift lever boot and bezel. (21) Connect battery negative cable.
21 - 78 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued) † release fork ball stud. † propeller shaft slip yoke. (2) Apply sealer to threads of bottom PTO coverbolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission.
mission under vehicle.
(4) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start input shaft in release bearing, clutch disc and pilot bush- ing.
(6) Work transmission forward until seated against clutch housing. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
(7) Install transmission bolts and tighten to 108
N·m (80 ft. lbs.).
rear crossmember.
fixture.
on shift cover.
(8) Install transmission mount on transmission or
(9) Install rear crossmember. (10) Remove transmission jack and engine support
(11) Position transmission harness wires in clips
(12) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(13) Connect speed sensor and backup light switch
wires.
TWO WHEEL DRIVE
(1) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(2) Align and install propeller shaft. (3) Lower vehicle. (4) Clean the mating surfaces of shift tower, isola- tor plate and shift cover with suitable wax and grease remover.
(5) Apply Mopar Gasket Maker or equivalent to the sealing surface of the shift cover. Do not over apply sealant.
(6) Install the isolator plate onto the shift cover,
metal side down.
(7) Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and the isolator plate.
(8) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(9) Install the bolts to hold the shift tower to the isolator plate and the shift cover. Tighten the shift tower bolts to 10.2-11.25 N·m (7.5-8.3 ft. lbs.).
(10) Install the shift lever extension onto the shift
tower and lever assembly.
(11) Install shift boot and bezel. (12) Connect battery negative cable.
DR MANUAL TRANSMISSION - NV4500 (Continued) SPECIFICATIONS
MANUAL TRANSMISSION - NV4500
21 - 79
TORQUE SPECIFICATIONS
DESCRIPTION
Switch, Back-up Lamp
Countershaft Bearing Plate Bolts
Fifth Gear Nut
Fifth Gear Nut Clamp Bolt
Drain and Fill Plug
Front Bearing Retainer Bolts Mainshaft Bearing Plate Bolts
PTO Cover Bolts
Extension/Adapter Housing Bolts
Shift Mechanism Cover Bolts
Transmission Bolts
SPECIAL TOOLS
N·m 22-34
19-26
366-38013.5
34-47
27-34
19-26
27-54
41-68
27-31
108Ft. Lbs. 16-25
14-19
270-28010
25-35
20-25
14-19
20-40
30-50
20-2380
In. Lbs.
170-230
235-305
170-230REMOVERC-3985-B
INSTALLERBUSHING6951
BUSHINGREMOVER6957
INSTALLERBUSHING8156
REMOVERBUSHING8155
HANDLEC-4171
