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21 - 80 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
INSTALLERSEALC-3972-A
INSTALLERSEAL8154
INSTALLERSEALC-3860-A
SOCKET6441
SOCKET6442
SOCKET6993
WRENCH6443
SOCKET6984
WRENCH6743
PULLER6444
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 81
JAWS6459
JAWS6451
JAWS6820
REMOVER6454
JAWS&INSERT6453
JAWS6447
JAWS6449
INSTALLER6061
INSTALLERC-4340
21 - 82 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
INSTALLERC-4040
RODEXTENSION8161
INSTALLER6448
INSTALLER6446
INSTALLERC-4308
JAWS6445
INSTALLER6052
DR
MANUAL TRANSMISSION - NV4500
21 - 83
ADAPTER HOUSING SEAL REMOVAL
(1) Raise and support vehicle. (2) Mark the propeller shafts and yokes for instal-
lation reference and remove the shafts.
(3) Support transmission with a transmission jack. (4) Remove engine rear support. (5) Remove transfer case. (6) Remove adapter housing seal with a pry tool or
slide hammer mounted screw (Fig. 131).
(3) Remove extension housing seal (Fig. 132) using
Remover C-3985-B.
(4) On heavy duty 4X2 vehicles, remove extension housing seal with a pry tool or a slide hammer mounted screw.
Fig.132EXTENSIONHOUSINGANDSEAL(4X2)
1 - EXTENSION HOUSING 2 - SEAL
(5) On light duty transmissions, remove the exten-
sion housing bushing with Remover 6957.
(6) On heavy duty transmissions,
remove the
extension housing bushing with Remover 8155.
Fig.131AdapterHousing(4–WheelDriveModels) 1 - ADAPTER HOUSING 2 - SEAL
INSTALLATION
INSTALLATION
(Fig. 133) and Installer.
(1) Install housing bushing with Handle C-4171
† Light Duty - Installer 6951
† Heavy Duty - Installer 8161(1) Install adapter housing seal with Installer
C-3860-A and Handle C-4171.
(2) Install transfer case. (3) Install propeller shafts with reference marks
(4) Fill transfer case and transmission to proper
aligned.
level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL REMOVAL
(1) Mark the propeller shaft and yoke for installa-
tion reference.
(2) Remove the propeller shaft.
Fig.133ExtensionHousingBushing
1 - HANDLE 2 - INSTALLER 3 - EXTENSION HOUSING
21 - 84 MANUAL TRANSMISSION - NV4500
EXTENSION HOUSING SEAL (Continued)(2) Install housing seal with Handle C-4171 (Fig. 134) and Installer. † Light Duty - Installer C-3972-A † Heavy Duty - Installer 8154
DR
(3) Pry up shift mechanism cover at slots provided
in cover (Fig. 136).
Fig.134PinionSeal
Fig.136LOOSENSHIFTMECHANISM
1 - HANDLE 2 - INSTALLER
1 - SHIFT MECHANISM COVER SLOT 2 - PRY TOOL
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
(4) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 137).
SHIFT MECHANISM REMOVAL
(1) Remove transmission from vehicle. (2) Remove shift mechanism cover bolts (Fig. 135).
Fig.137SHIFTMECHANISMCOVER
1 - SHIFT MECHANISM COVER 2 - ALIGNMENT DOWELS
(5) Raise front of shift mechanism cover and lift
cover up and off gear case (Fig. 137).
Fig.135SHIFTMECHANISMBOLTS
1 - SHIFT MECHANISM COVER 2 - BOLTS
DR SHIFT MECHANISM (Continued) FIFTH-REVERSE SHIFT FORK PADS
Three shift pads on the forks are held in place by
tension and a small locating tang (Fig. 138).
MANUAL TRANSMISSION - NV4500
21 - 85
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of Mopar silicone sealer or
equivalent to outer edge of each new plug.
(2) Position each plug in bore and tap into place
with hammer and punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab. (2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift mechanism
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 mechanism cover.
Fig.138SHIFTFORKPADLOCATIONS
1 - SHIFT FORK PADS 2 - FIFTH-REVERSE FORK
To remove the pads, grasp a pad with hand and tilt it out and off the fork. If pad is difficult to remove by hand, insert a screwdriver blade between the pad and fork and pry the pad off.
EXPANSION PLUG
The expansion plugs at the rear of the shift rail
bores (Fig. 139) can be replaced if loose/leaking.
CAUTION: Do not use an excessive 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. 140) are secure.
Fig.139EXPANSIONPLUGLOCATION
1 - EXPANSION PLUGS
(1) Drill 6 mm (1/4 in.) diameter hole in center of
the plug to be removed.
(2) Pry plug out of cover with tapered punch. (3) Clean all chips from shift cover and plug bores. Then clean plug bores with solvent and dry with clean shop towel.
Fig.140SHIFTFORKPAD
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 mechanism cover on trans-
mission.
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.
21 - 86 MANUAL TRANSMISSION - NV4500
SHIFT MECHANISM (Continued)DR
(7) Apply Mopar Lock N’ Seal or equivalent to
INSTALLATION
threads of shift cover bolts.
(8) Install shift cover mechanism 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.
(11) Install transmission.
SHIFT COVER REMOVAL
(1) Shift transmission into Neutral. (2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission shift cover.
(5) Remove the shift tower and isolator plate from
the transmission shift cover.
(1) Clean the mating surfaces of shift tower, isola- tor plate and shift cover with suitable wax and grease remover.
(2) Apply Mopar Gasket Maker or equivalent to the sealing surface of the shift cover. Do not over apply sealant.
(3) Install the isolator plate onto the shift cover,
metal side down.
(4) Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and the isolator plate.
(5) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(6) Install bolts to hold the shift tower to the iso- lator plate and the shift cover. Tighten the shift tower bolts to 10.2-11.25 N·m (7.5-8.3 ft. lbs.).
(7) Install shift lever extension, shift boot and
bezel.
DR
MANUAL TRANSMISSION - NV5600
21 - 87
MANUAL TRANSMISSION - NV5600
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NV5600
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 122
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 87
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 89
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 90
CLEANING - TRANSMISSION . . . . . . . . . . . . . 104
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 104
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
. . . . . . . . . . . . . . 122
SPECIFICATIONS - NV5600MANUAL TRANSMISSION - NV5600
DESCRIPTIONThe NV5600 is a six speed constant mesh manual transmission (Fig. 1). All gear ranges including reverse are synchronized. First and second gears uti- lize dual cone synchronizers in order to aid shifting. Sixth gear is an overdrive range. The transmission uses cast iron for the gear case and extension/ adapter housing and aluminum for the clutch hous- ing.
ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 127EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 127SHIFT COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 128To drain the trans remove the bottom PTO cover bolt. Fill the trans through the plug to the rear of the PTO cover (Fig. 1). Dry fill is approximately 4.5 liters (9.5 pints) or to the bottom edge of the fill plug hole.
The gear ratios are:
GEAR RATIOS
GEAR FIRST
SECOND
THIRD FOURTH
FIFTH SIXTH
REVERSE
RATIO 5.63:1
3.38:1
2.04:1
1.39:1
1.00:1
0.73:1
5.63:121 - 88 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
Fig.1NV5600MANUALTRANSMISSION
DR MANUAL TRANSMISSION - NV5600 (Continued) IDENTIFICATION
The transmission has
two identification tags attached to the driver side upper clutch housing (Fig. 2). One tag provides the transmission part number. The second tag provides sequencing and build date information. The information on the tags are essen- tial to correct parts ordering.
MANUAL TRANSMISSION - NV5600
21 - 89
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.
Fig.2IDENTIFICATIONTAGLOCATION
1 - IDENTIFICATION TAGS
OPERATION
The driver selects a particular gear by moving the shift lever to the desired gear position. As the shift lever moves the selected shift rail, the shift fork attached to that rail begins to move. The fork is posi- tioned in a groove in the outer circumference of the synchronizer sleeve. As the shift fork moves the syn- chronizer sleeve, the synchronizer begins to speed-up or slow down the selected gear (depending on whether we are up-shifting or down-shifting). The synchronizer 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 friction 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 synchronizer sleeve become aligned with the teeth on the blocker ring and friction cone and eventually will slide over the teeth, locking the gear to the main- shaft 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
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 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.
21 - 90 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(2) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(3) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(4) Remove the shift tower and isolator plate from
the transmission gear case.
(5) Raise and support vehicle. (6) Remove skid plate, if equipped. (7) Mark propeller shaft/shafts and axle yokes for
installation reference.
(8) Remove propeller shaft. (9) Disconnect and remove exhaust system as nec-
essary.
(10) Disconnect wires at backup light switch. (11) Support engine with adjustable safety stand
and wood block.
(12) If
transmission is to be disassembled for repair, remove drain bolt at bottom of PTO cover and drain lubricant from transmission (Fig. 3).
FOUR WHEEL DRIVE
fer case range lever.
(1) Disconnect transfer case shift linkage at trans-
(2) Support and secure transfer case with safety
chains to a transmission jack.
(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
bolts/nuts
attaching
transmission
mount to rear crossmember.
(8) Remove rear crossmember bolts and pry out
crossmember.
the engine block.
clears clutch disc.
vehicle.
(9) Remove transmission clutch housing bolts at
(10) Move transmission rearward until input shaft
(11) Lower transmission and remove it from under
DISASSEMBLY
NOTE: Use Fixture 8241 for moving and handling the transmission. The fixture supports the transmis- sion at the center of gravity in order to ease mount- ing the transmission into the build fixture.
(1) Mount the transmission into Fixture 8230 (Fig. 4).
Fig.3NV5600DRAINBOLT
1 - PTO COVER 2 - DRAIN BOLT
(13) Remove clutch slave cylinder splash shield, if
equipped.
(14) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(15) Remove wire harness from clips on transmission.
TWO WHEEL DRIVE
the rear mount.
(1) Remove bolts/nuts mounting transmission to
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmember.
the engine block.
(4) Remove transmission clutch housing bolts at
(5) Slide transmission and jack rearward until
input shaft clears clutch disc and pressure plate.
(6) Lower transmission jack and remove transmis-
sion from under vehicle.
Fig.4TRANSMISSIONFIXTURE
1 - FIXTURE 2 - TRANSMISSION
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 91
(4) Remove primary shift rail detent plug (Fig. 7).
Fig.7PRIMARYSHIFTRAILDETENTPLUG
1 - DETENT PLUG
(5) Remove primary shift rail detent spring (Fig.
8).
Fig.8PRIMARYSHIFTRAILDETENTSPRING
1 - DETENT SPRING
(2) Rotate the transmission to the horizontal posi-
(3) Remove the shift tower (Fig. 5) and isolator
tion, if necessary.
plate (Fig. 6).
Fig.5REMOVESHIFTTOWER
1 - SHIFT TOWER 2 - TRANSMISSION
Fig.6SHIFTTOWERISOLATORPLATE
1 - ISOLATOR PLATE 2 - TRANSMISSION
21 - 92 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(6) Remove primary shift rail detent plunger (Fig.
9).
DR
Fig.9PRIMARYSHIFTRAILDETENTPLUNGER
1 - DETENT PLUNGER
(7) Remove clutch housing bolts (10) (Fig. 10) from
inside the housing.
Fig.11SHIFTRAILBLOCKERBOLT
1 - BLOCKER BOLT
(2) Remove extension/adapter housing from the
transmission gear case with Puller 8244 (Fig. 12).
NOTE: It may be necessary to straighten the hous- ing during removal due to the tendency for the reverse idler shaft the housing.
to bind into one side of
Fig.10CLUTCHHOUSINGBOLTS
1 - BOLTS (10)
(8) Remove shift rail blocker bolt (Fig. 11) from the
side of the transmission gear case.
EXTENSION/ADAPTER HOUSING
(1) Remove bolts holding the extension/adapter
housing onto the transmission gear case.
Fig.12TRANSMISSIONCASEPULLER
1 - PULLER 2 - EXTENSION/ADAPTER HOUSING
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 93
(3) Remove crossover detent plug, spring and plunger from the extension/adapter housing (Fig. 13).
NOTE: Tag all countershaft pre-load shims from between the bearing race and the housing (Fig. 16).
(8) Remove crossover cam bushing from the exten-
sion/adapter housing with Remover 8240.
Fig.13CROSSOVERCAMDETENTPLUG
1 - DETENT PLUG 2 - EXTENSION HOUSING
(4) Remove bolt and washer holding the crossover
cam to the extension/adapter housing (Fig. 14).
(5) Remove crossover cam from the extension/
adapter housing.
Fig.14CROSSOVERCAMBOLT
1 - CROSSOVER CAM 2 - BOLT 3 - EXTENSION HOUSING
(6) Remove back-up lamp switch from the exten-
sion/adapter housing.
(7) Remove countershaft rear bearing race from the extension/adapter housing with Remover L-4518
(Fig. 15).Fig.15COUNTERSHAFTREARBEARINGRACE
1 - REMOVER
Fig.16COUNTERSHAFTREARBEARINGRACE
ANDSHIM
1 - PRE-LOAD SHIM 2 - BEARING RACE
(9) On 4X2 vehicles, remove extension housing
seal with a pry tool or a slide hammer and screw.
(10) On 4X4 vehicles, remove adapter housing seal
with a pry tool or a slide hammer and screw.
21 - 94 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
REVERSE GEAR
(1) Remove crossover cam rollers and pin (Fig. 17).
(4) Remove reverse idler gear rear bearing, bear- ing spacer, front bearing and front thrust washer from the idler gear shaft.
(5) Remove reverse countershaft rear bearing from the countershaft reverse gear assembly with Puller C-293-PA and Adapters C-293-52 (Fig. 19).
Fig.17CROSSOVERCAMROLLERSANDPIN
1 - CROSSOVER CAM PIN 2 - CROSSOVER CAM ROLLERS
(2) Remove reverse idler thrust washer from the
reverse idler.
(3) Remove reverse idler and reverse countershaft
gears together (Fig. 18).
Fig.19COUNTERSHAFTREARBEARINGPULLER 1 - PULLER 2 - ADAPTERS
(6) Seperate countershaft reverse gear and sleeve. (7) Remove output shaft nut with Wrench 8226 on the shaft nut and Socket 6993 or 6984 to hold the shaft (Fig. 20). Discard output shaft nut from the output shaft.
NOTE: If necessary strike the flat side area of Wrench 8226 with a hammer to break the nut loose.
Fig.18REVERSEIDLERANDCOUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR 2 - COUNTERSHAFT REVERSE GEAR
Fig.20LOOSENOUTPUTSHAFTNUT
1 - WRENCH 2 - SOCKET
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 95
(8) Remove output shaft ball bearing assembly and reverse thrust washer from the output shaft (Fig. 21).
(10) Remove reverse gear bearing sleeve from the
output shaft (Fig. 23).
NOTE: If necessary heat the sleeve slightly with a heat gun. Do not use a torch to heat the sleeve or damage to the output shaft may occur.
Fig.21OUTPUTSHAFTBEARINGANDTHRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING 2 - THRUST WASHER
(9) Remove reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring and reverse gear bearing (Fig. 22).
Fig.23REVERSEBEARINGSLEEVE
1 - REVERSE GEAR BEARING SLEEVE
(11) Remove roll-pin securing the reverse shift fork to the reverse shift rail with a 6 mm (7/32 in.) punch and hammer.
Fig.22REVERSEGEARCOMPONENTS
1 - REVERSE GEAR 2 - REVERSE BEARING 3 - BLOCKER RING 4 - FRICTION CONE
21 - 96 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(12) Remove reverse shift fork and synchronizer as an assembly from the reverse shift rail and the out- put shaft (Fig. 24).
DR
Fig.25TRANSMISSIONCASELIFTFIXTURE
1 - FIXTURE 2 - TRANSMISSION CASE
Fig.24REVERSESHIFTFORKANDSYNCHRO
1 - REVERSE SYNCHRO 2 - REVERSE SHIFT FORK
TRANSMISSION GEAR CASE
(1) Remove remaining bolts holding the transmis-
sion gear case to the clutch housing.
(2) Remove the shift socket roll pin with a 6 mm
(7/32 in.) punch and hammer.
(3) Turn shift socket so it won’t catch the case
when lifting it up.
case.
(4) Install Fixture 8232 to the transmission gear
(5) Attach an engine crane or equivalent to Fixture 8232 and remove the transmission gear case from the clutch housing (Fig. 25).
(6) Remove rear output shaft and countershaft bearing races from the transmission gear case with a brass drift and hammer.
GEARTRAIN
(1) Remove bolts holding the 5-6 crossover bracket
to the clutch housing (Fig. 26).
Fig.265-6CROSSOVERBRACKETBOLTS
1 - 5-6 CROSSOVER BRACKET
DR MANUAL TRANSMISSION - NV5600 (Continued)
(2) Attach Fixture 8232 to the output shaft and
countershaft (Fig. 27).
MANUAL TRANSMISSION - NV5600
21 - 97
Fig.27FIXTURE/OUTPUTSHAFT
1 - OUTPUT SHAFT 2 - FIXTURE
Fig.28RemoveHoldingTool
1 - HOLDING TOOL 2 - 5-6 SYNCHRO
(3) Attach an engine crane or equivalent to Fixture 8232 and raise the geartrain approximately 1/4 in. from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
ing.
(5) Lower the geartrain back into the clutch hous-
(6) Install Holding Tool 8242 (Fig. 28) onto the 5-6
synchro and tighten the screw to hold the 5-6 syn- chro together during the removal operation.NOTE: Note the order of the shift fork arms at the primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
rails
from the rest of
the
(8) Remove shift geartrain (Fig. 29).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig.29SHIFTRAILS
1 - 5-6 SHIFT RAIL
21 - 98 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(10) Remove geartrain from the clutch housing and install the geartrain into Support Stand 8246 (Fig. 30).
DR
Fig.31FRONTCOUNTERSHAFTBEARING
1 - PULLER 2 - JAWS
Fig.30GEARTRAINFIXTURE
1 - FIXTURE 2 - SUPPORT STAND
(11) Remove Fixture 8232 from the output shaft
and the countershaft.
(12) Separate the countershaft from the output
shaft.
(13) Separate the output shaft from the input shaft. Hold the 5-6 synchro together while removing the output shaft to prevent the synchro sleeve from being dislodged from the synchro hub.
COUNTERSHAFT BEARINGS
(1) Remove snap-ring holding the front counter-
shaft bearing onto the countershaft.
(2) Remove front countershaft bearing with Collar 6444-8, Jaws 6451, Puller Rods 6444-4 and Puller 6444 (Fig. 31).
(3) Remove rear countershaft bearing with Collar 6444-8, Jaws 6447, Puller Rods 6444-4, Puller 6444
and suitable press button (Fig. 32).Fig.32REARCOUNTERSHAFTBEARING
1 - PULLER 2 - JAWS
DR MANUAL TRANSMISSION - NV5600 (Continued)
OUTPUT SHAFT BEARINGS
MANUAL TRANSMISSION - NV5600
21 - 99
(1) Remove snap-ring holding the pocket bearing
onto the output shaft.
(2) Remove pocket bearing from the output shaft with Sleeve 6444-8, Jaws 8234, Puller Rods 6444-4
and the remainder of Puller 6444 (Fig. 33).(3) Remove snap-ring holding the rear output shaft
bearing onto the output shaft.
(4) Use Collar 6444-8, Jaws 8271 and Puller Rods 6444-3 for 4X2 vehicles or Puller Rods 6444-4 for 4X4
vehicles with the remainder of Puller 6444 to remove the rear output shaft bearing from the output shaft. (5) Remove rear output shaft thrust washer fromthe output shaft.
Fig.33OUTPUTSHAFTPOCKETBEARING
1 - PULLER 2 - JAWS
INPUT SHAFT
(1) Remove fifth gear blocker ring from the input
(2) Remove fifth gear friction cone from the input
shaft (Fig. 34).
shaft (Fig. 35).
Fig.34FIFTHGEARBLOCKERRING
1 - FIFTH GEAR BLOCKER RING 2 - INPUT SHAFT
Fig.35FIFTHGEARFRICTIONCONE
1 - FRICTION CONE 2 - INPUT SHAFT
21 - 100 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 36).
DR
Fig.37INPUTSHAFTBEARING
1 - PULLER 2 - JAWS
Fig.36OUTPUTSHAFTPOCKETBEARINGRACE 1 - PULLER 2 - INPUT SHAFT
(4) Remove input shaft bearing and oil guide from the input shaft with Collar 6444-8, Jaws 8243, Puller Rods 6444-6 and the remainder of Puller 6444 (Fig. 37).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be installed backwards. Mark the gears, clutch gears, synchro hubs, and sleeves for installation reference during disassembly. Use paint or a scribe for mark- ing purposes. Then stack the geartrain parts in order of removal.
(1) Remove first gear from the output shaft. (2) Remove first gear bearing from the output
shaft (Fig. 38).
(3) Remove first gear blocker rings (2) and cones
from the 1-2 synchro assembly (Fig. 39).
(4) Install the remainder of the output shaft into
Fixture 8227 with press blocks under second gear.
(5) Install shaft and Fixture assembly into a shop
press (Fig. 40).
(6) Press second gear, 1-2 synchro assembly and
first gear bearing sleeve from the output shaft.
(7) Remove second gear bearing from the output
shaft.
Fig.38FIRSTGEARBEARING
1 - OUTPUT SHAFT 2 - FIRST GEAR BEARING
(8) Reverse output shaft in the Fixture 8227 with press blocks positioned under the 5-6 synchro assem- bly.
(9) Press the 5-6 synchro assembly from the out-
put shaft.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 101
(10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 41).
Fig.39FIRSTGEARBLOCKERRINGSAND
FRICTIONCONE
1 - OUTPUT SHAFT 2 - FIRST GEAR BLOCKER RINGS 3 - FIRST GEAR FRICTION CONE
Fig.41SIXTHGEARCOMPONENTS
1 - SIXTH GEAR FRICTION CONE 2 - SIXTH GEAR 3 - OUTPUT SHAFT 4 - SIXTH GEAR BLOCKER RING 5 - 5-6 SYNCHRO
Fig.40SECONDGEAR,1-2SYNCHRO&FIRST
GEARBEARINGSLEEVE
1 - OUTPUT SHAFT 2 - FIRST GEAR BEARING SLEEVE 3 - SECOND GEAR 4 - FIXTURE 5 - 1-2 SYNCHRO
21 - 102 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)COUNTERSHAFT
(1) Install the countershaft into Fixture 8227 with press blocks located under the fifth countershaft gear.
(2) Place the assembly into a shop press. (3) Use Guide 8235 on end of countershaft and press the countershaft fifth gear from the counter- shaft (Fig. 42).
DR
Fig.43SIXTHCOUNTERSHAFTGEAR
1 - GUIDE 2 - SIXTH COUNTER SHAFT GEAR 3 - FIXTURE
Fig.42FIFTHCOUNTERSHAFTGEAR
1 - GUIDE 2 - FIFTH COUNTER SHAFT GEAR 3 - FIXTURE
(4) Place countershaft in Fixture 8227 with press
blocks placed under the sixth countershaft gear.
(5) Use Guide 8235 on end of countershaft and press the countershaft sixth gear from the counter- shaft (Fig. 43).
(6) Remove countershaft from the press and Fix-
ture 8227.
(7) Remove fourth countershaft gear, friction cone, blocker ring and bearing from the countershaft (Fig. 44).
(8) Install countershaft
into Fixture 8227 with press blocks located under the third countershaft gear.
Fig.44FOURTHCOUNTERSHAFTGEAR
COMPONENTS
1 - FOURTH GEAR BLOCKER RING 2 - FOURTH GEAR BEARING 3 - COUNTERSHAFT 4 - FOURTH GEAR FRICTION CONE 5 - FOURTH COUNTERSHAFT GEAR
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 103
(9) Place assembly into a shop press and press third countershaft gear, 3-4 synchro and fourth coun- tershaft gear bearing sleeve from the countershaft (Fig. 45).
Fig.46THIRDGEARBEARING
1 - COUNTERSHAFT 2 - 2-3 THRUST WASHER 3 - THIRD COUNTERSHAFT GEAR BEARING
Fig.45THIRDCOUNTERSHAFTGEAR
COMPONENTS
1 - THIRD COUNTERSHAFT GEAR 2 - FIXTURE 3 - 3-4 SYNCHRO 4 - BEARING SLEEVE 5 - COUNTERSHAFT
(10) Remove countershaft from the press and Fix-
ture 8227.
(11) Remove third countershaft gear bearing from
the countershaft (Fig. 46).
(12) The 2-3 thrust washer should not normally need to be removed from the countershaft. If neces- sary slide 2-3 thrust washer off countershaft.
CLUTCH HOUSING
(1) Remove input shaft retainer bolts from the
clutch housing and remove retainer (Fig. 47).
Fig.47INPUTSHAFTRETAINER
1 - INPUT SHAFT RETAINER 2 - CLUTCH HOUSING
21 - 104 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(2) Remove countershaft oil guide from the coun- tershaft front bearing bore in the clutch housing (Fig. 48).
DR
Fig.49FRONTCOUNTERSHAFTBEARINGRACE 1 - CLUTCH HOUSING 2 - HANDLE 3 - REMOVER
Fig.48COUNTERSHAFTOILGUIDE
1 - CLUTCH HOUSING 2 - COUNTERSHAFT OIL GUIDE
(3) Remove countershaft front bearing race, end- play shims and spacer from the clutch housing with Remover 6061-1 and Handle C-4171 (Fig. 49).
(4) Remove input shaft bearing race with Remover/
Installer 8237 and Handle C-4171.
(5) Remove input shaft oil guide and retainer seal
(Fig. 50).
CLEANING - TRANSMISSION
Clean the gears, bearings shafts, extension/adapter housing and gear case with solvent. Dry all parts except the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
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
Fig.50OILGUIDEANDSEAL
1 - INPUT SHAFT OIL GUIDE 2 - INPUT SHAFT OIL SEAL
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.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 105
Inspect the countershaft and bearings. Replace the shaft if any surfaces exhibit considerable wear or dam- age.
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, pit- ting or other damage. Replace the bearings if necessary. 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 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 Gasket Maker or equivalent on all gear case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Place second gear on bench with the synchro
clutch ring up.
(2) Install second gear synchro inner blocker ring
onto second gear (Fig. 51).
(3) Install second gear synchro friction cone over
the blocker ring and onto second gear (Fig. 52).
Fig.52FRICTIONCONE
1 - GEAR 2 - FRICTION CONE
(4) Install second gear synchro outer blocker ring over the second gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 53).
Fig.53OUTERBLOCKERRING
1 - OUTER BLOCKER RING 2 - LUG 3 - GEAR
Fig.51INNERBLOCKERRING
1 - INNER BLOCKER RING 2 - GEAR
21 - 106 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(5) Install 1-2 synchro assembly onto the second
gear assembly (Fig. 54).
DR
Fig.543-4SYNCHROASSEMBLY
1 - SYNCHRO 2 - GEAR
(6) Reverse assembly on the bench. (7) Lubricate and install second gear bearing into
second gear (Fig. 55).
Fig.56OUTPUTSHAFTINTO1-2SYNCHRO
1 - OUTPUT SHAFT 2 - 1-2 SYNCHRO 3 - SECOND GEAR
(13) Install first gear synchro friction cone over the
blocker ring and onto first gear (Fig. 52).
(14) Install first gear synchro outer blocker ring over the first gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 53).
(15) Reverse the output shaft in the press. (16) Install first gear bearing sleeve onto the out-
put shaft.
Fig.55SECONDGEARANDBEARING
1 - BEARING 2 - GEAR
(8) Place 1-2 synchro, second gear and second gear bearing assembly on shop press with second gear fac- ing upward.
(9) Install output shaft into the second gear 1-2
synchro assembly with the front of the output shaft facing upward (Fig. 56).(10) Press the output shaft into position. (11) Place first gear on bench with the synchro
clutch ring up.
(12) Install first gear synchro inner blocker ring
onto first gear (Fig. 51).
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 107
(17) Install first gear bearing sleeve the remainder of the way onto the output shaft using Installer 8228
and a shop press (Fig. 57).Fig.57FIRSTGEARBEARINGSLEEVE
1 - INSTALLER 2 - FIRST GEAR BEARING SLEEVE
Fig.58FIRSTGEARANDBLOCKERASSEMBLY
1 - OUTPUT SHAFT 2 - FIRST GEAR ASSEMBLY
(18) Install first gear and blocker assembly onto
the output shaft (Fig. 58).
(19) Install first gear bearing over the output shaft
and into first gear.
output shaft (Fig. 59).
(20) Install output shaft thrust washer onto the
Fig.59OUTPUTSHAFTTHRUSTWASHER
1 - OUTPUT SHAFT 2 - OUTPUT SHAFT THRUST WASHER
21 - 108 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(21) Install rear output shaft bearing onto the out- put shaft with Installer 8228 and a shop press (Fig. 60).
(22) Install a new snap-ring to hold the rear out- put bearing onto the output shaft. Install the thick- est snap-ring which will fit into the groove.
DR
Fig.61SIXTHGEAR
1 - SIXTH GEAR 2 - SIXTH GEAR BEARING
Fig.62SIXTHGEARBLOCKERRING
1 - SIXTH GEAR BLOCKER RING 2 - SIXTH GEAR FRICTION CONE
Fig.60REAROUTPUTSHAFTBEARING
1 - INSTALLER 2 - REAR OUTPUT SHAFT BEARING
(23) Reverse output shaft in the Fixture 8227 and support the shaft with press blocks under first gear. (24) Install sixth gear bearing onto the output
shaft.
gear.
(25) Install sixth gear onto the output shaft and
over the sixth gear bearing (Fig. 61).
(26) Install the sixth gear friction cone onto sixth
(27) Install sixth gear blocker ring over the sixth
gear friction cone (Fig. 62).
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 109
(28) Install Guide 8235 onto the end of the output
shaft (Fig. 63).
Fig.63OUTPUTSHAFTGUIDE
1 - GUIDE 2 - OUTPUT SHAFT
Fig.645-6SYNCHRO
1 - INSTALLER 2 - 5-6 SYNCHRO
(29) Install 5-6 synchro over Guide 8235 and onto
the output shaft.
(30) Press 5-6 synchro (Fig. 64) onto the output
shaft with Installer 8156 and a shop press.
(31) Install output shaft pocket bearing onto the
output shaft.
(32) Press pocket bearing the remainder of the way onto the output shaft using Guide 8235 and a shop press (Fig. 65).
(33) Install a new snap-ring to hold the output
shaft pocket bearing onto the output shaft.
Fig.65OUTPUTSHAFTPOCKETBEARING
1 - GUIDE 2 - POCKET BEARING
21 - 110 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)COUNTERSHAFT
DR
(1) Place third countershaft gear on the bench
with the synchro clutch ring up.
(2) Install third countershaft gear friction cone
onto third gear (Fig. 66).
Fig.683-4SYNCHROASSEMBLY
1 - SYNCHRO 2 - GEAR
Fig.66FRICTIONCONEANDTHIRDGEAR
1 - FRICTION CONE 2 - GEAR 3 - CLUTCH RING
(3) Install
third countershaft gear blocker ring
onto the friction cone (Fig. 67).
Fig.67BLOCKERRINGONTOFRICTIONCONE
1 - BLOCKER RING 2 - GEAR 3 - FRICTION CONE
(4) Install 3-4 synchro assembly onto the blocker
ring/gear assembly (Fig. 68).
(5) Reverse the assembly on the bench. (6) Install third countershaft gear bearing into the
third countershaft gear.
(7) Install 2-3 thrust washer onto the countershaft. (8) Place third gear/3-4 synchro assembly in a shop
press.
(9) Install countershaft through the third gear/3-4
(10) Press
countershaft
into
the 3-4 synchro
synchro assembly.
assembly (Fig. 69).
Fig.69COUNTERSHAFTINTO3-4SYNCHRO
1 - COUNTERSHAFT 2 - 2-3 THRUST WASHER 3 - THIRD COUNTERSHAFT GEAR
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 111
(11) Install fourth countershaft gear bearing sleeve
(19) Install countershaft into the fourth/sixth coun-
tershaft gear assembly in the shop press.
(20) Press countershaft into sixth gear (Fig. 71).
CAUTION: Gear and shaft must be aligned while pressing or the gear will bind on the shaft.
onto the output shaft.
(12) Press fourth countershaft bearing sleeve onto the countershaft with Installer 8228 and a shop press.
(13) Place fourth countershaft gear on the bench
with the synchro clutch ring up.
(14) Install fourth countershaft gear friction cone
onto fourth countershaft gear (Fig. 66).
(15) Install fourth countershaft gear blocker ring
onto the friction cone (Fig. 67).
(16) Install fourth countershaft gear bearing into
the fourth countershaft gear.
(17) Place sixth countershaft gear in the shop
press.
(18) Position fourth countershaft gear assembly
onto the sixth countershaft gear (Fig. 70).
Fig.70FOURTHCOUNTERSHAFTONTOSIXTH
COUNTERSHAFTGEAR
Fig.71COUNTERSHAFTINTOSIXTHGEAR
1 - FOURTH BEARING 2 - FOURTH COUNTERSHAFT GEAR 3 - SIXTH COUNTERSHAFT GEAR
1 - COUNTERSHAFT 2 - SIXTH COUNTERSHAFT GEAR 3 - 3-4 SYNCHRO
(21) Place fifth countershaft gear into the shop
press.
21 - 112 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(22) Install countershaft into the fifth countershaft gear and press countershaft into fifth gear (Fig. 72).
CAUTION: Gear and shaft must be aligned while pressing or the gear will bind on the shaft.
(23) Place front countershaft bearing onto the
countershaft. (24) Install
front countershaft bearing onto the countershaft with Installer 8236 and Handle C-4171. (25) Install a new snap-ring to hold the front
countershaft bearing onto the countershaft.
(26) Place rear countershaft bearing onto the coun-
tershaft.
INPUT SHAFT
(1) Place the input shaft bearing onto the input
shaft.
(2) Install
input MD998805 (Fig. 73).
shaft bearing with Installer
Fig.72COUNTERSHAFTTOFIFTH
COUNTERSHAFTGEAR
1 - COUNTERSHAFT 2 - FIFTH COUNTERSHAFT GEAR
Fig.73INPUTSHAFTBEARING
1 - INSTALLER 2 - INPUT SHAFT BEARING
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 113
(3) Position the input shaft bearing oil guide on
the input shaft (Fig. 74).
Fig.75OUTPUTSHAFTPOCKETBEARINGRACE 1 - HANDLE 2 - INPUT SHAFT 3 - INSTALLER
Fig.74INPUTSHAFTOILGUIDE
1 - INPUT SHAFT 2 - INPUT SHAFT OIL GUIDE
(4) Install
input shaft bearing oil guide with
Installer MD998805.
the input shaft.
(5) Place the output shaft pocket bearing race in
(6) Install output shaft pocket bearing race into the input shaft with Installer C-4628 and Handle C-4171 (Fig. 75).
CLUTCH HOUSING
(1) Install
input shaft bearing race so that the bearing race protrudes 0.3 in. above the front surface of the clutch housing. Install bearing race with Remover/Installer 8237 and Handle C-4171.
(2) Install countershaft front bearing race into the clutch housing so that the bearing race protrudes 0.4
in. above the front surface of the clutch housing. Install bearing race with Remover 6061-1 and Han- dle C-4171.(3) Install countershaft oil guide and spacer into the countershaft front bearing bore in the clutch housing (Fig. 76).
(4) Clean all old sealer from the input shaft retainer and the clutch housing but DO NOT apply
Fig.76OILGUIDEANDSPACER
1 - 0.3 IN. BEYOND FLUSH 2 - 0.4 IN. BEYOND FLUSH
new sealer at this time. New sealer will be applied after all the preload measurements are made and end-play shims are installed.
21 - 114 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
NOTE: Do not replace the input shaft seal at this time. A new seal will be installed after all the pre- load measurements are made and endplay shims are installed.
(5) Install
input shaft retainer onto the clutch housing and install bolts to hold the input shaft retainer.
GEARTRAIN
(5) Install countershaft into the Support Stand 8246 and verify that all gears are meshed with their mates on the output shaft (Fig. 78).
(1) Install input shaft into Support Stand 8246. (2) Install fifth gear friction cone onto the input
(3) Install fifth gear blocker ring onto the fifth
gear friction cone.
(4) Install output shaft into the input shaft (Fig.
shaft.
77).
Fig.78COUNTERSHAFTWITHOUTPUTSHAFT
1 - COUNTERSHAFT 2 - OUTPUT SHAFT 3 - SUPPORT STAND
Fig.77OUTPUTSHAFTANDINPUTSHAFT
1 - OUTPUT SHAFT 2 - INPUT SHAFT 3 - SUPPORT STAND
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 115
(6) Install Fixture 8232 to the output shaft and
countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro and tighten the screw to hold the 5-6 synchro together during the remainder of the installation pro- cedure.
(8) Attach a engine crane or equivalent to Fixture 8232 and move the geartrain from the Support Stand 8246 to the clutch housing (Fig. 79).
Fig.80SHIFTRAILSINSTALLED
1 - SHIFT RAILS
(11) With the geartrain approximately 1/4 in. from the clutch housing, remove Holding Tool 8242 from the 5-6 synchro (Fig. 81).
Fig.79GEARTRAINFIXTURE
1 - FIXTURE 2 - SUPPORT STAND
(9) Install shift forks and rails onto the geartrain
(Fig. 80).
NOTE: The closest shift arm to the geartrain is for Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.(10) Install geartrain and shift rails into the clutch housing. Lower the geartrain and rails into the hous- ing slowly while guiding input shaft through input shaft seal. Avoid any binds on the shift rails, forks and synchros as the rails enter their bushings.
Fig.81HOLDINGTOOL
1 - HOLDING TOOL 2 - 5-6 SYNCHRO
CAUTION: Do not damage input shaft seal with the input shaft splines.
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.
21 - 116 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts and
tighten to 28 N·m (20 ft. lbs.) (Fig. 82).
Fig.825-6CROSSOVERBRACKETBOLTS
1 - 5-6 CROSSOVER BRACKET
Fig.83LIFTFIXTURE
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
1 - FIXTURE 2 - TRANSMISSION CASE
TRANSMISSION GEAR CASE
(1) Install rear output shaft bearing race into the transmission gear case with Installer C-4308 and Handle C-4171.
(2) Install rear countershaft bearing race into the transmission gear case with Installer 8153 and Han- dle C-4171.
(3) Install Fixture 8232 to the transmission gear
case.
NOTE: Shift socket must be loose on the shift shaft and is rotated a minimum of 90° from its normal position. This will ensure enough clearance to install the transmission gear case.
(4) Apply sealant to the clutch housing. (5) Attach an engine crane or equivalent to Fixture 8232 and install the transmission gear case onto the clutch housing (Fig. 83).
(6) Install clutch housing bolts and tighten to 48
N·m (35 ft.lbs.).
(7) Install shift socket roll pin with a suitable 6
mm (7/32 in.) punch and hammer.
MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use Socket 6993 to rotate the shafts and seat the bear- ings.
(2) Measure mainshaft endplay with Dial Indicator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case (Fig. 84).
Fig.84MEASUREMAINSHAFTENDPLAY
1 - DIAL INDICATOR 2 - EXTENSION ROD 3 - MAIN SHAFT
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 117
(3) Measure countershaft end-play with Dial Indi- cator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case (Fig. 85).
Fig.86REVERSESHIFTFORKANDSYNCHRO
1 - REVERSE SYNCHRO 2 - REVERSE SHIFT FORK
(2) Install roll-pin securing the reverse shift fork to the reverse shift rail with 6 mm (7/32 in.) punch and a hammer.
(3) Install reverse gear bearing sleeve onto the output shaft with Installer 6446 if necessary (Fig. 87).
Fig.85MEASURECOUNTERSHAFTEND-PLAY
1 - EXTENSION ROD 2 - DIAL INDICATOR 3 - COUNTERSHAFT
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play of 0-0.10 mm (0-0.004 in.) for the mainshaft and countershaft.
NOTE: Countershaft shims go between the bearing race and spacer. Mainshaft shims go into the input shaft retainer.
(6) Install a new input shaft seal into the input
shaft retainer with Installer C-4965.
(7) Install input shaft oil guide with C-3972-A and
Handle C-4171.
(8) Apply sealer to the input shaft retainer and install retainer onto the clutch housing. Install bolts and tighten to 28 N·m (20 ft.lbs.).
REVERSE GEAR
(1) Install reverse shift fork and synchronizer as an assembly onto the reverse shift rail and output shaft (Fig. 86).
NOTE: Raised square shoulder and snap-ring on the synchro face the case.
Fig.87REVERSEBEARINGSLEEVE
1 - REVERSE GEAR BEARING SLEEVE
21 - 118 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(4) Install reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring and reverse gear bearing (Fig. 88).
DR
Fig.89OUTPUTSHAFTBEARINGANDTHRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING 2 - THRUST WASHER
(11) Install reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer onto the idler gear shaft.
(12) Install
idler and reverse countershaft gears
together (Fig. 90).
Fig.88REVERSEGEARCOMPONENTS
1 - REVERSE GEAR 2 - REVERSE BEARING 3 - BLOCKER RING 4 - FRICTION CONE
(5) Install output shaft ball bearing assembly and reverse thrust washer onto the output shaft (Fig. 89).
NOTE: Raised shoulder on thrust washer faces away from the reverse gear.
Fig.90REVERSEIDLERANDCOUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR 2 - COUNTERSHAFT REVERSE GEAR
(6) Install a new output shaft nut onto the output
shaft.
(7) With Wrench 8226 on the output shaft nut and Socket 6993 or 6984 holding the output shaft, tighten the nut to 339 N·m (250 ft.lbs.).
(8) Stake nut into the slot in the output shaft with
a 9 mm (5/16 in.) punch.
(9) Press countershaft reverse gear into the sleeve
with a shop press.
(10) Install reverse countershaft rear bearing onto the countershaft reverse gear assembly with Installer C-4652 and Handle C-4171.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 119
(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
Fig.91CROSSOVERCAMROLLERSANDPIN
1 - CROSSOVER CAM PIN 2 - CROSSOVER CAM ROLLERS
EXTENSION/ADAPTER HOUSING
Fig.92MeasureHeightofReverseCountershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
extension
(1) Install
bushing with Installer 8156 and Handle C-4171, if necessary. The oil feed hole must be at the 12 o’clock position when installed.
housing
(2) On 4X2 vehicles, install extension housing seal with Installer 8154 and Handle C-4171, with the weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion of toward the ground) when installed.
face downward (
the seal must
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install
the crossover cam bushing into the extension/adapter housing with Installer 8239 and Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(10) Place Gauge Bar 6311 across the housing face. Measure the distance from the top of the bar to the bottom of the reverse countershaft bearing race bore (Fig. 93).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.
Fig.93MEASUREDEPTHOFREVERSE
COUNTERSHAFTGEARBEARINGRACEBORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
(12) The difference between the two measurements is the end-play for the reverse countershaft gear assembly. (13) Install shims to achieve 0.15-0.25 mm (0.006- 0.010 in.) end-play for the reverse countershaft gear assembly into the reverse countershaft bearing race bore.
21 - 120 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(14) Use Installer to install the reverse counter- shaft bearing race into the extension/adapter hous- ing.
(15) Install back-up lamp switch into the exten- sion/adapter housing and tighten to 28 N·m (20
ft.lbs.).(16) Install
crossover
cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 94).
(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter housing onto the transmission gear case. Tighten bolts to 48 N·m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N·m (41 ft.lbs.).
(23) Install primary shift
rail detent plunger, spring and plug into the transmission case. Tighten detent plug to 47.5 N·m (35 ft.lbs.).
(24) Install shift tower onto the transmission case
and tighten bolts to 9 N·m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com- ponents supplied with the transmission. If a new shift tower is supplied with the new transmission, do not re-use the original shift tower.
(1) Apply a light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of following components:
† input shaft splines. † release bearing slide surface of front retainer.
