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ing bolt is located on the bottom side of the sleeve.
TRACK BAR REMOVAL
(1) Raise and support the axle. (2) Remove the track bar bolts and nuts (Fig. 8). (3) Remove the track bar (Fig. 8).
INSTALLATION
(1) Install the track bar. (2) Install the new bolts and nuts. Tighten to 203
N·m (150 ft lbs.).
Fig.8TRACKBARREMOVAL/INSTALLATION
1 - TRACK BAR 2 - BOLT 3 - NUT
(3) Remove the supports under the axle and lower
the vehicle to the ground.
19 - 38
PUMP
PUMP
TABLE OF CONTENTS
page
DR
page
PUMP
INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 39
STANDARD PROCEDURESTANDARD PROCEDURE - POWER
INSTALLATION - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . 43INSTALLATION - PRESSURE HOSE INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER . . . . . . . . . . . . . . . 43
STEERING PUMP - INITIAL OPERATION . . . . 39
HOSES - LINK/COIL
STANDARD PROCEDURE - FLUSHING
REMOVAL
POWER STEERING SYSTEM . . . . . . . . . . . . 39
REMOVAL - RETURN HOSE - GEAR TO
REMOVAL
REMOVAL - GAS . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . 40INSTALLATION
INSTALLATION - GAS INSTALLATION - DIESEL
. . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . 41SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 41
FLUID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
STANDARD PROCEDURE - POWERSTEERING FLUID LEVEL CHECKING . . . . . . 42
FLUID COOLER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 43
REMOVAL - RETURN HOSE - RESERVOIRTO COOLER . . . . . . . . . . . . . . . . . . . . . . . . . 43
PUMP DESCRIPTION
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley.
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 44
REMOVAL - RETURN HOSE - RESERVOIRTO COOLER . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . 44INSTALLATION - PRESSURE HOSE INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER . . . . . . . . . . . . . . . 44
POWER STEERING PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL - 3.7L, 4.7L & 5.7L . . . . . . . . . . . . . . 45
. . . . . . . . . . 45
INSTALLATION - 3.7L, 4.7L & 5.7LPULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange- able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer- ing gear by the belt driven power steering pump (Fig. 1). The power steering pumps are constant flow rate and displacement, vane-type pumps.
DR PUMP (Continued)
PUMP
19 - 39
(1) Turn steering wheel all the way to the left (2) Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground. (4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid level.NOTE: For vehicles with long return lines or oil coolers turn wheel 40 times.
Fig.1POWERSTEERINGPUMP
1 - 3.7L & 4.7L (6 GROOVE) PHENOLIC (PLASTIC TYPE) PULLEY 1 - 5.7L,5.9L & 8.0L (7 GROOVE) PHENOLIC (PLASTIC TYPE) PULLEY 1 - 5.9L DIESEL (8 GROOVE) STEEL PULLEY 2 - PUMP ASSEMBLY 3 - RESERVOIR 4 - CAP
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir o-rings can be replaced. Check for leaks in the following areas: † Pump shaft seal behind the pulley † Pump to reservoir O-ring † Reservoir cap † Pressure and return lines † Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION
THE FLUID LEVEL SHOULD BE WARNING: CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS.
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature.
(5) Start the engine. With the engine idling main-
tain the fluid level.
for two minutes.
(6) Lower the front wheels and let the engine idle
(7) Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER STEERING SYSTEM
Flushing is required when the power steering/hy- draulic booster system fluid has become contami- nated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steer- ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: booster remove both return lines from the pump.
If vehicle is equipped with a hydraulic
(3) Plug the return line port/ports at the pump. (4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
(6) With the engine running at idle turn the wheel
start the engine.
back and forth.
NOTE: Do not contact or hold the wheel against the steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering Pump Initial Operation, (Refer to 19 - STEERING/ PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
PUMP
19 - 40
PUMP (Continued)(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again.
(12) Install
Steering Pump Initial Operation, STEERING/PUMP - STANDARD PROCEDURE).
the return line/lines and perform (Refer to 19 -
REMOVAL
REMOVAL - GAS
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67Nm, 40 - 50 lbft) If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled prop- erly. If this occurs the pump needs to be replaced with a new pump.
(3) Disconnect the return hose. (Fig. 2) (4) Disconnect the pressure hose. (Fig. 2) (5) Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes. (Fig. 2)
DR
REMOVAL - DIESEL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67Nm, 40 - 50 lbft) If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled prop- erly. If this occurs the pump needs to be replaced with a new pump.
(3) Disconnect the return hose. (4) Disconnect the pressure hose. (5) Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes.
(6) Loosen the pump bracket to the block. (7) Remove the 6 intake plenum bolts (Fig. 3). (8) loosen the inner cooler tube clamp at intake plenum and remove the intake plenum.
the
(9) Loosen the inner cooler tube clamp at the radi- ator support side and remove the tube from the vehi- cle.
(10) Remove the power steering pump from the top of the engine compartment where the intake plenum was (Fig. 3).
Fig.2POWERSTEERINGPUMP
1 - INTAKE PLENUM MOUNTING 2 - POWER STEERING PUMP
Fig.3POWERSTEERINGPUMPACCESS
1 - POWER STEERING PULLEY 2 - POWER STEERING RESERVOIR 3 - RETURN HOSE 4 - HIGH PRESSURE HOSE
DR PUMP (Continued) INSTALLATION
INSTALLATION - GAS
left cylinder head.
(1) Align the pump with the mounting holes in the
(2) Install 3 pump mounting bolts through the pul- ley access holes. Tighten the bolts to 28 N·m (21 ft. lbs.).
(3) Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 37 N·m (27 ft. lbs.).
(4) Install the serpentine drive belt, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
PUMP
19 - 41
INSTALLATION - DIESEL
(1) Set the power steering pump in place in the
engine compartment from the top (Fig. 3).
(2) Install the inner cooler tube. (3) Tighten the inner cooler tube clamp at the
radiator support side.
(4) Install the 6 intake plenum bolts (Fig. 3). (5) Tighten the inner cooler tube clamp at the
intake plenum.
(6) Install 3 pump mounting bolts through the pul- ley access holes. Tighten the bolts to 28 N·m (21 ft. lbs.).
(7) Tighten the pump bracket to the block. (8) Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 37 N·m (27 ft. lbs.).
(9) Install the serpentine drive belt, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(10) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
Power Steering Pressure
Switch
Power Steering Line
Pressure Line
Power Steering Line
Return Line
Power Steering Line
Pressure Line To Pump Power Steering Pump
Mounting Bolts
Power Steering Pump
Reservoir Bolts
Power Steering Pump
Bracket Bolts
TORQUE SPECIFICATIONS
N·m 10
32
71
37
28
Ft. Lbs.
In. Lbs.
—
23
52
27
27
80
—
—
—
—
—
—
19 - 42
PUMP
FLUID DESCRIPTION
DR
(3) Remove the mounting bracket bolts securing
the fluid cooler to the brace. (Fig. 4)& (Fig. 5) (4) Remove the fluid cooler from the vehicle.
The recommended fluid for the power steering sys-
tem is Mopart ATF +4.
Mopart ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or anti- freeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.
STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS.
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
Fig.4V6&V8P/SFLUIDCOOLER
1 - POWER STEERING FLUID COOLER 2 - MOUNTING BOLTS
The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold.
Use only Mopart ATF+4 Do not overfill the
power steering system.
FLUID COOLER REMOVAL
(1) Drain and siphon the power steering fluid. (2) Disconnect the return and supply hoses con-
nected to the power steering fluid cooler.
Fig.5V10&DIESELP/SFLUIDCOOLER
1 - RADIATOR 2 - POWER STEERING HOSES 3 - MOUNTING BOLTS 4 - P/S FLUID COOLER
INSTALLATION
(1) Install the fluid cooler to the vehicle. (2) Install the mounting bracket bolts securing the
fluid cooler to the brace (Fig. 4)& (Fig. 5).
(3) Reclamp the return and supply hoses to the
power steering fluid cooler.
(4) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
DR
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO COOLER
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the return hose at the cooler. (4) Disconnect the return hose at the gear (Fig. 6). (5) Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle.
Fig.6HOSECONNECTIONS
1 - RETURN HOSE 2 - PRESSURE HOSE
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the pressure hose at the pump. (4) Disconnect the pressure hose at the gear (Fig.
6).
PUMP
19 - 43
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reconnect the return hose at the gear. Tighten
the hose to 71 N·m (52 ft. lbs.) (Fig. 6).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle. (2) Reconnect
the pressure hose at
the gear.
Tighten the hose to 32 N·m (23 ft. lbs.) (Fig. 6).
(3) Reconnect
the pressure hose at Tighten the hose to 36 N·m (27 ft. lbs.).
the pump.
(4) Remove the support and lower the vehicle. (5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle. (5) Reconnect the return hose at the reservoir. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(5) Remove the pressure hose from the vehicle.
HOSES - LINK/COIL
REMOVAL - RETURN HOSE - RESERVOIR TO COOLER
REMOVAL
(1) Drain and siphon the power steering system. (2) Disconnect the return hose at the reservoir. (3) Raise and support the vehicle. (4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler. (6) Remove the hose from the vehicle.
REMOVAL - RETURN HOSE - GEAR TO COOLER
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the return hose at the cooler. (4) Disconnect the return hose at the gear (Fig. 7). (5) Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle.
PUMP
19 - 44
HOSES - LINK/COIL (Continued)DR
REMOVAL - RETURN HOSE - RESERVOIR TO COOLER
(1) Drain and siphon the power steering system. (2) Disconnect the return hose at the reservoir. (3) Raise and support the vehicle. (4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler. (6) Remove the hose from the vehicle.
Fig.7POWERSTEERINGHOSESTOSTEERING
GEAR
1 - HIGH PRESSURE HOSE 2 - RETURN HOSE 3 - STEERING GEAR
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system. (2) Raise and support the vehicle. (3) Disconnect the pressure hose at the pump. (4) Disconnect the pressure hose at the gear (Fig.
8).
Fig.8HOSESINSTALLED
1 - LOWER COUPLING BOLT 2 - HIGH PRESSURE HOSE 3 - RETURN HOSE 4 - STEERING GEAR 5 - PITMAN ARM
(5) Remove the pressure hose from the vehicle.
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reconnect the return hose at the gear. Tighten
the hose to 71 N·m (52 ft. lbs.) (Fig. 7).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle. (2) Reconnect
the pressure hose at
the gear.
Tighten the hose to 32 N·m (23 ft. lbs.) (Fig. 8).
(3) Reconnect
the pressure hose at Tighten the hose to 36 N·m (27 ft. lbs.).
the pump.
(4) Remove the support and lower the vehicle. (5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER
(1) Install the return hose to the vehicle. (2) Reconnect the return hose at the cooler. (3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle. (5) Reconnect the return hose at the reservoir. (6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
DR
PUMP
19 - 45
POWER STEERING PRESSURE SWITCH DESCRIPTION
A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose (Fig. 9). This switch will be used with both 3.7L, 4.7L and 5.7L engines. There is no pres- sure switch used for the 5.9L pump.
OPERATION
The switch is used on the 3.7L V-6, 4.7L & 5.7L
V-8 engines.
The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during park- ing maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load.
When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting.REMOVAL - 3.7L, 4.7L & 5.7L
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Disconnect electrical
connector
from power
steering pressure switch.
(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 3.7L, 4.7L & 5.7L
This switch is used only with the 3.7L V–6 and the
4.7L, 5.7L V-8 engines.
(1) Install power steering switch into power steer-
ing line.
sary.
(2) Tighten to 8–11 N·m (70–100 in. lbs.) torque. (3) Connect electrical connector to switch. (4) Check power steering fluid and add as neces-
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
Fig.9PRESSURESWITCH
1 - POWER STEERING PULLEY 2 - POWER STEERING PUMP HOUSING 3 - POWER STEERING FLUID RESERVOIR 4 - RETURN HOSE 5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
PULLEY REMOVAL
CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pul- ley must be installed if removed.
(1) Remove the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - REMOVAL).
(2) Remove the pulley from the pump with an appropriate power steering pulley removal tool (Fig. 10).
Fig.10PULLEYREMOVAL
1 - POWER STEERING PUMP 2 - PULLEY 3 - POWER STEERING PULLEY REMOVAL TOOL
PUMP
19 - 46
PULLEY (Continued) INSTALLATIONCAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pul- ley must be installed if removed.
(1) Replace the pulley if it’s bent, cracked, or loose. (2) Install the pulley on the pump with an appro- priate power steering pulley installation tool (Fig. 11) making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft.
Fig.11PULLEYINSTALLATION
1 - POWER STEERING PUMP 2 - PULLEY 3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL
(3) Install
the power steering pump assembly, (Refer to 19 - STEERING/PUMP - INSTALLATION). (4) Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward
DR
approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts.
RESERVOIR REMOVAL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt. (3) Remove the power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove the reservoir mounting bolts. (5) Remove the reservoir. (6) Remove the rear bracket to the pump mounting
bolts.
INSTALLATION
(1) Install the reservoir bracket to the pump hous- ing. Do not reuse the o-rings (install new o-rings). Tighten bolts to 7 N·m (5 ft. lbs.).
NOTE: Ensure the reservoir is fully seated onto the pump.
(2) Install the reservoir to the bracket/pump body. (3) Install the reservoir mounting bolts. Tighten
bolts to 7 N·m (5 ft. lbs.).
(4) Install the power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(5) Install the serpentine drive belt, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(6) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
DR
TRANSMISSION AND TRANSFER CASE
21 - 1
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV5600
AUTOMATIC TRANSMISSION - 46RE AUTOMATIC TRANSMISSION - 48RE. . . . . . . . . . 1
. . . . . . . . . . 42
. . . . . . . . . . 87
. . . . . . . . 129
. . . . . . . . 310AUTOMATIC TRANSMISSION - 45RFE/545RFE TRANSFER CASE - NV241 GENII TRANSFER CASE - NV271
TRANSFER CASE - NV243
TRANSFER CASE - NV273. . 488
. . . . . . . . . . . 591
. . . . . . . . . . . . . . . . 623
. . . . . . . . . . . . . . . . 658
. . . . . . . . . . . . . . . . 687MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NV3500
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 4CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . 40
SPECIAL TOOLSMANUAL TRANSMISSION - NV3500
DESCRIPTIONThe transmission is a medium-duty 5-speed, con- stant mesh fully synchronized manual transmission with fifth gear overdrive range. The transmission is available in two and four-wheel drive configurations. The transmission gear case consists of two aluminum housings (Fig. 1). The clutch housing is an integral part of the transmission front housing.
A combination of roller and ball bearings are used to support the transmission shafts in the two hous- ings. The transmission gears all rotate on caged type needle bearings. A roller bearing is used between the input and output shaft.
The transmission has a single shaft shift mecha- nism with three shift forks all mounted on the shaft. The shaft is supported in the front and rear housings by bushings and one linear ball bearing. Internal shift components consist of the forks, shaft, shift lever socket and detent components
OPERATION
The manual transmission receives power through the clutch assembly from the engine. The clutch disc is
splined to the transmission input shaft and is turned at engine speed at all times that the clutch is engaged. The input shaft is connected to the transmission coun- tershaft through the mesh of fourth speed gear on the input shaft and the fourth countershaft gear. At this point, all the transmission gears are spinning.
The driver selects a particular gear by moving the shift lever to the desired gear position. This move- ment moves the internal transmission shift compo- nents to begin the shift sequence. As the shift lever moves the selected shift rail, the shift fork attached to that rail begins to move. The fork is positioned in a groove in the outer circumference of the synchro- nizer sleeve. As the shift fork moves the synchronizer sleeve, the synchronizer begins to speed-up or slow down the selected gear (depending on whether we are up-shifting or down-shifting). The synchronizer does this by having the synchronizer hub splined to the mainshaft 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 the friction cone and eventually will slide over the teeth, locking the gear to the mainshaft, or countershaft, through the synchronizer.
21 - 2 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
Fig.1NV3500TRANSMISSION
DR MANUAL TRANSMISSION - NV3500 (Continued) 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. Leaks can occur at the mating surfaces of the gear case, adaptor or exten- sion housing, or from the front/rear seals. A sus- pected leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous- ing will be from the housing oil seals. Leaks at com- ponent 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 dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the clutch disc caus- ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a minute or so before checking. These rec- ommendations 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.
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.
Shift component damage or damaged clutch pres- sure plate or disc are additional probable causes of increased shift effort. 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.
MANUAL TRANSMISSION - NV3500
21 - 3
Severe highly audible transmission noise is gener- ally the initial indicator of a lubricant problem. Insufficient, 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 and bearing damage.
REMOVAL
(1) Disconnect battery negative cable. (2) Shift transmission into Neutral. (3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Raise vehicle on hoist. (6) Remove skid plate, if equipped. (7) Drain lubricant if transmission will be disas-
sembled for service.
(8) Mark propeller shaft/shafts and companion installation reference and
for
flange yoke/yokes remove propeller shaft/shafts.
(9) Disconnect harness from clips on transmission
housing.
(10) Remove transfer case linkage if equipped. (11) Remove transfer case mounting nuts and
remove transfer case if equipped.
(12) Remove slave cylinder mounting nut and
remove cylinder (Fig. 2).
Fig.2SLAVECYLINDER
1 - MOUNTING NUTS 2 - SLAVE CYLINDER
21 - 4 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(13) Remove starter motor, structural dust cover,
dust shield and suspension crossmember (Fig. 3).
Fig.3DUSTCOVER
1 - DUST SHIELD 2 - STARTER MOTOR 3 - DUST COVER 4 - CROSSMEMBER
(14) Remove exhaust pipe from the exhaust mani-
folds.
and wood block.
(15) Support engine with adjustable jack stand
(16) Support and secure transmission to a trans-
mission jack with safety chains.
(17) Remove bolts from the rear transmission
mount.
sion mount (Fig. 4).
(18) Remove the rear crossmember and transmis-
(19) Remove bolts attaching transmission to the
engine.
(20) Move transmission rearward until input shaft is clear of clutch disc and pressure plate. Then lower jack and remove transmission from under vehicle.
DISASSEMBLY
FRONT HOUSING
(1) Shift transmission into Neutral. (2) If lubricant was not drained out of transmis- sion during removal, remove drain plug and drain lubricant.
(3) Inspect drain plug magnet for debris. (4) Remove backup light switch located on passen-
ger side of rear housing (Fig. 5).
Fig.5BACKUPLIGHTSWITCH
1 - BACKUP LIGHT SWITCH
(5) Remove shift tower bolts and remove tower and
lever assembly (Fig. 6).
Fig.4CROSSMEMBER
1 - TRANSMISSION MOUNT 2 - CROSSMEMBER
1 - SHIFT TOWER 2 - SHIFT SOCKET 3 - SEAL
Fig.6SHIFTTOWER
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 5
(6) Remove shift shaft lock bolt (Fig. 7) from the top of front housing. The bolt secures the shift shaft bushing and lever.
NOTE: This is a special bolt and can not be substi- tuted with any other bolt.
(8) Remove bearing retainer from input shaft (Fig.
9).
Fig.9INPUTSHAFTBEARINGRETAINER
1 - SHAFT BEARING 2 - BEARING RETAINER 3 - INPUT SHAFT
Fig.7SHAFTLOCKBOLT
(9) Remove input shaft snap ring (Fig. 10).
1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET
(7) Remove input shaft bearing retainer bolts from the front housing, then carefully pry on the retainer to break sealer bead loose (Fig. 8).
Fig.10INPUTSHAFTSNAPRING
1 - INPUT SHAFT SNAP RING 2 - OIL FEED
Fig.8BEARINGRETAINERSEAL
1 - PRY TOOL 2 - INPUT SHAFT BEARING RETAINER
21 - 6 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(10) Remove shift shaft detent plug from the side of the transmission with Remover 8117A. Attach fin- gers of the remover to the detent plug and push the cup down till it contacts the trans. Then tighten the nut till it pulls the plug from the case.
(11) Remove shift shaft detent plunger and spring
with a pencil magnet.
(12) Remove bolts that attach front housing to the rear housing (Fig. 11). Three bolts at extreme rear of housing are for the output shaft bearing retainer. Leave one bolt in place until geartrain is ready to be removed from case.
(13) Separate the housings (Fig. 12) by tapping the front housing off alignment dowels with a plastic hammer.
Fig.12FRONTHOUSING
1 - FRONT HOUSING 2 - REAR HOUSING 3 - DOWELS (2) 4 - PLASTIC MALLET
(14) Remove input shaft bearing and countershaft
front bearing race (Fig. 13).
Fig.11HOUSING&BEARINGRETAINERBOLT
1 - RETAINER BOLTS 2 - HOUSING BOLTS 3 - RETAINER BOLT 4 - HOUSING BOLT LOCATIONS
Fig.13InputShaftBearingandCountershaftFront
BearingRace
1 - INPUT SHAFT BEARING 2 - FRONT HOUSING 3 - COUNTERSHAFT FRONT BEARING
DR MANUAL TRANSMISSION - NV3500 (Continued)
(15) Note position of input shaft, shift shaft, forks
and geartrain components in housing (Fig. 14).
MANUAL TRANSMISSION - NV3500
21 - 7
Fig.15DETENTSPRINGANDBALL
1 - SHAFT LEVER 2 - SPRING AND BALL 3 - MAGNET
Fig.16SHIFTSOCKET
1 - REMOVER 2 - SHIFT SOCKET
Fig.14GEARTRAINANDSHIFTCOMPONENT
1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER AND SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT 7 - 1-2 FORK 8 - INPUT SHAFT 9 - 3-4 FORK
SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT
(1) Place a shop towel over the shaft lever to con-
tain the lever detent ball and spring.
(2) Rotate lever and bushing upward out of the
shift forks and catch ball and spring (Fig. 15).
(3) Unseat shift socket roll pin with Remover 6858. Position remover on shift shaft and center tool over the roll pin. Verify tool legs are firmly seated on the shift socket (Fig. 16).
(4) Tilt socket toward the side of the case to avoid
trapping the pin between the gear teeth.
(5) Tighten remover to press the roll pin down-
ward and out of the shift socket (Fig. 16).
NOTE: Roll pin must only clear the shift shaft. Do not push the pin into the geartrain.
(6) Drive out shift bushing and lever roll pin with
a hammer and punch (Fig. 17).
NOTE: Use proper size punch to avoid bending the shift shaft.
Fig.17SHIFTSHAFTLEVER&BUSHINGROLLPIN 1 - PIN PUNCH 2 - BUSHING AND LEVER 3 - SHIFT SHAFT
21 - 8 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(7) Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork and 1-2 fork (Fig. 18).
(10) Rotate 3-4 fork around synchro sleeve until fork clears shift arms on 1-2 and fifth-reverse forks, then remove 3-4 fork (Fig. 21).
Fig.18SHIFTSHAFT
1 - SHIFT SHAFT 2 - 3-4 FORK 3 - SHAFT DETENT NOTCHES
(8) Remove shift socket from rear housing (Fig. 19).
Fig.213-4SHIFTFORK
1 - 3-4 FORK 2 - 1-2 AND 5TH-REVERSE FORK ARMS 3 - 3-4 SYNCHRO SLEEVE
(11) Remove reverse idler shaft support bolt and
loosen rear reverse idler shaft bolt (Fig. 22).
Fig.19SHIFTSOCKET&ROLLPIN
1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET
(9) Remove shaft lever and bushing (Fig. 20).
Fig.20SHIFTSHAFTLEVER&BUSHING
1 - SHAFT LEVER AND BUSHING 2 - 3-4 FORK
Fig.22REVERSEIDLERSHAFT&SUPPORT
1 - SUPPORT BOLT 2 - SHAFT BOLT
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 9
(12) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(13) Support geartrain and rear housing on Fix-
ture 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2A on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 23).
(d) Stand geartrain and rear housing upright on fixture (Fig. 24). Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position.
Fig.23FIXTUREASSEMBLY
1 - FIXTURE 6747
2 - ADAPTER 6747-1A 3 - CUP ADAPTER 8115
4 - REVERSE IDLER PEDESTAL 5 - ADAPTER 6747-2A(14) Remove rear bolt holding reverse idler shaft
in housing.
REAR HOUSING - 2WD
(1) On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (Fig. 25). Bolts are rear of shift tower open- ing.
Fig.24GEARTRAIN&HOUSINGONFIXTURE
1 - INPUT SHAFT 2 - COUNTERSHAFT 3 - FIXTURE 6747
Fig.25OUTPUTSHAFT
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT IS AT OPPOSITE SIDE OF CASE)
21 - 10 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(2) Tap rear housing upward and off output shaft
bearing with a plastic/rawhide hammer (Fig. 26).
DR
Fig.26SEPARATEREARHOUSING&OUTPUT
SHAFTBEARING
1 - REAR HOUSING 2 - MALLET 3 - FIXTURE
(3) Lift rear housing up and off geartrain (Fig. 27). (4) Remove countershaft rear bearing from coun-
tershaft (Fig. 28).
Fig.27REARHOUSING-2WD
1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN
Fig.28COUNTERSHAFTREARBEARING
1 - COUNTERSHAFT REAR BEARING 2 - OUTPUT SHAFT 3 - COUNTER SHAFT
DR MANUAL TRANSMISSION - NV3500 (Continued) REAR ADAPTER HOUSING - 4WD
(1) Inserting screw from slide hammer (Fig. 29) into one of the dimples in face of rear seal (Fig. 30) and remove seal.
MANUAL TRANSMISSION - NV3500
21 - 11
(2) Remove rear bearing snap ring from output
shaft (Fig. 31).
Fig.29REARSEAL
1 - SLIDE HAMMER 2 - REMOVER TOOL 3 - REAR SEAL
Fig.31REARBEARINGSNAPRING
1 - HEAVY DUTY SNAP RING PLIERS 2 - REAR BEARING SNAP RING 3 - OUTPUT SHAFT
(3) Lift rear adapter housing upward and off
geartrain (Fig. 32).
Fig.30REARSEALFACE
1 - DIMPLES 2 - SEAL FACE
Fig.32REARADAPTERHOUSING
1 - REAR ADAPTER HOUSING 2 - OUTPUT SHAFT
21 - 12 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(4) Remove bearing retainer bolts and remove rear bearing retainer and rear bearing (Fig. 33). Push or tap bearing out of housing with a hammer handle if needed.
NOTE: Housing must be replaced if race, bearing bore or idler shaft notch are worn or damaged.
(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Position Bearing Splitter 1130 between second and third gears and press off 3-4 synchro assembly, third gear synchro ring and third gear with a shop press.
(3) Remove third gear needle bearing (Fig. 34).
Fig.34THIRDGEARNEEDLEBEARING
1 - THIRD GEAR NEEDLE BEARING
(4) Remove retaining ring that secures two-piece thrust washer on shaft with a small pry tool (Fig. 35).
Fig.33REARADAPTERHOUSINGCOMPONENTS 1 - BEARING RETAINER 2 - RETAINER BOLTS (3) 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT REAR BEARING RACE 5 - REAR BEARING
GEARTRAIN FROM FIXTURE
(1) Remove reverse idler gear assembly from
assembly fixture cup.
chro sleeves.
(2) Remove 1-2 and fifth-reverse forks from syn-
(3) Slide countershaft out of fixture tool. (4) Remove output shaft bearing retainer from rear surface of fifth gear (retainer will drop onto gear after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from the fixture.
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different and must not be mixed. Remove each synchronizer unit as an assembly to avoid mixing parts. Mark each synchro hub and sleeve with a scriber or paint for correct assembly reference.
Fig.35THRUSTWASHER
1 - PRY TOOL 2 - THRUST WASHER RETAINING RING
DR MANUAL TRANSMISSION - NV3500 (Continued)
(5) Remove two-piece thrust washer (Fig. 36) and note position of washer locating lugs in shaft notches for installation reference.
MANUAL TRANSMISSION - NV3500
21 - 13
Fig.38SECONDGEARSYNCHRORING&CONES 1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - INTERM RING 3 - SYNCHRO FRICTION CONE 4 - SYNCHRO CONE 5 - SYNCHRO RING
Fig.36TWO-PIECETHRUSTWASHER
1 - SECOND GEAR 2 - THRUST WASHER (2-PIECE) 3 - WASHER LOCATING LUG
(6) Remove second gear and needle bearing (Fig.
37).
Fig.39HUBSLEEVE&1-2SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - BEARING SPLITTER 1130
Fig.37SECONDGEAR
1 - SECOND GEAR 2 - SECOND GEAR NEEDLE BEARING
(7) Remove second gear synchro ring, synchro fric-
tion cone, synchro cone and interm ring (Fig. 38).
(8) Remove 1-2 synchro hub snap ring. (9) Position Bearing Splitter 1130 between first and reverse gear. Press off 1-2 synchro hub, sleeve and first gear from output shaft with shop press (Fig. 39).
(10) Remove first gear needle bearing (Fig. 40).
Fig.40FIRSTGEARNEEDLEBEARING
1 - FIRST GEAR NEEDLE BEARING
21 - 14 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(11) Remove output shaft bearing snap ring (Fig. 41).
(15) Remove fifth-reverse synchro hub snap ring
(Fig. 44).
Fig.41OUTPUTSHAFTBEARINGSNAPRING
1 - OUTPUT SHAFT BEARING 2 - BEARING SNAP RING 3 - SNAP RING PLIERS
(12) On 2-wheel drive models, remove output shaft
bearing.
(13) Remove fifth gear (Fig. 42).
Fig.44FIFTH-REVERSESYNCHROHUBSNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 2 - SYNCHRO HUB SNAP RING 3 - SNAP RING PLIERS
(16) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 45).
Fig.42FIFTHGEAR
1 - FIFTH GEAR AND SYNCHRO RING
(14) Remove fifth gear needle bearing. Spread bearing
just enough to clear shoulder on output shaft (Fig. 43).
Fig.43FIFTHGEARNEEDLEBEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig.45FIFTH-REVERSESYNCHRO
1 - PRESS 2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 3 - REVERSE GEAR 4 - OUTPUT SHAFT
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 15
(17) Remove reverse gear and needle bearing (Fig.
46).
INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball or internal components are worn or damaged.
SHIFT SHAFT AND FORKS
Fig.46REVERSEGEAR&NEEDLEBEARING
1 - REVERSE GEAR AND NEEDLE BEARING
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47). (2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and transmission housings with a standard parts clean- ing solvent. Do not use acid or corrosive base sol- vents. Dry all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk or similar sol- vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
Inspect the shift fork interlock arms and synchro sleeve contact surfaces (Fig. 48). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks.
Check condition of the shift shaft detent plunger and spring. The plunger should be smooth and free of nicks or scores. The plunger spring should be straight and not collapsed, or distorted. Minor scratches or nicks on the plunger can be smoothed with 320/400 grit emery soaked in oil. Replace the plunger and spring if in doubt about condition. Check condition of detent plunger bushings. Replace if dam- aged.
Inspect shift shaft, shift shaft bushing, bearing, shaft lever and lever bushing that fits over the lever. Replace shaft if bent, cracked or severely scored. Minor burrs, nicks or scratches can be smoothed off with 320/400 grit emery cloth followed by polishing with crocus cloth. Replace the shift shaft bushing or bearing if damaged.
Replace the shaft lever and bushing if either part is deformed, or worn. Do not attempt to salvage these parts as shift fork binding will occur. Replace the roll pin that secures the lever to the shaft.
1 - SNAP RING 2 - FLAT WASHER 3 - WAVE WASHER 4 - THRUST WASHER 5 - REVERSE IDLER GEAR
Fig.47ReverseIdlerComponents
6 - IDLER GEAR BEARING 7 - IDLER SHAFT 8 - THRUST WASHER 9 - SNAP RING 10 - THRUST WASHER LOCKBALLS
21 - 16 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
1 - SHIFT SHAFT 2 - SHAFT LEVER 3 - SHAFT LEVER BUSHING
Fig.48ShiftForksAndShaft
4 - 3-4 SHIFT FORK 5 - 1-2 SHIFT FORK 6 - FIFTH-REVERSE SHIFT FORK
FRONT/REAR HOUSINGS AND BEARING RETAINERS
Inspect the housings carefully. Look for cracks, stripped threads, scored mating surfaces, damaged bearing bores or worn dowel pin holes. Minor nicks on mating surfaces can be dressed off with a fine file or emery cloth. Damaged threads can be renewed by either re-tapping or installing Helicoil inserts.
NOTE: The front housing contains the countershaft front bearing race. The rear housing contains the countershaft rear bearing race. These components are NOT serviceable items. The front housing will have to be replaced if the countershaft bearing race is loose, worn or damaged. The rear housing will have to be replaced if the countershaft rear bearing race is loose, worn or damaged.
Inspect the input shaft bearing retainer. Be sure the release bearing slide surface of the retainer is in good condition. Minor nicks on the surface can be smoothed off with 320/420 grit emery cloth and final polished with oil coated crocus cloth. Replace the retainer seal if necessary. shaft
the U-shaped retainer must be flat and free of distortion. Replace the retainer if the threads are damaged or if the retainer is bent or cracked.
retainer,
bearing
Inspect
output
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine lapped during manufacture to form matched sets. The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit in the housings and are NOT serviceable. If a bear- ing race becomes damaged, the front or rear hous- ing must be replaced. A new countershaft bearing will be supplied with each new housing for service use.
REVERSE IDLER COMPONENTS
Inspect
the idler gear, bearing,
thrust washer, wave washer and thrust plate. Replace the bearing if any of the needle bearing rollers are worn, chipped, cracked, flat-spotted or brinnelled. Also replace the bearing if the plastic bearing cage is damaged or distorted.
shaft,
Replace thrust washer, wave washer or thrust plate if cracked, chipped or worn. Replace idler gear if the teeth are chipped, cracked or worn thin. Replace shaft if worn, scored or the bolt threads are damaged beyond repair. Replace support segment if cracked or chipped and replace the idler attaching bolts if the threads are damaged.
DR MANUAL TRANSMISSION - NV3500 (Continued) Shift Socket
MANUAL TRANSMISSION - NV3500
21 - 17
Inspect
the shift socket
for wear or damage. Replace the socket if the roll pin or shift shaft bores are damaged. Minor nicks in the shift lever ball seat in the socket can be smoothed down with 400 grit emery or wet/dry paper. Replace the socket if the ball seat is worn or cracked. Do not reuse the original shift socket roll pin. Install a new pin during assem- bly. The socket roll pin is approximately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro- ken teeth. Also check condition of the bearing bore in each gear. The bores should be smooth and free of surface damage. Discoloration of the gear bores is a normal occurrence and is not a reason for replace- ment. Replace gears only when tooth damage has occurred or if the bores are brinnelled or severely scored.
Inspect the shaft splines and bearings surfaces. Minor nicks on the bearing surfaces can be smoothed with 320/420 grit emery and final polished with cro- cus cloth. Replace the shaft if the splines are dam- aged or bearing surfaces are deeply scored, worn or brinnelled.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use Mopar Gasket Maker or equivalent for all case joints and Mopar silicone sealer or equivalent for the input shaft bearing retainer.
SYNCHRONIZER
(1) Slide sleeve onto the hub, leaving enough room to install the spring in the hub and strut in the hub groove.
(2) Install first spring in the hub, then install a strut over the spring. Verify spring is seated in the spring bore in the strut.
(3) Slide sleeve onto the hub far enough to hold
the first strut and spring in place.
(4) Place detent ball in the top of the strut, then press the ball into place with a small screwdriver. Work the sleeve over the ball to hold it in place.
(5) Repeat procedure for the remaining springs, struts and balls. Use tape or rubber bands to tempo- rarily secure each strut and ball as they are installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 49).
Fig.49SYNCHRONIZERCOMPONENTS
1 - SLEEVE 2 - HUB SHOULDER 3 - SPRING (3) 4 - STRUT (3) 5 - DETENT BALL (3) 6 - HUB
OUTPUT SHAFT
shaft, gears, bearings
and NOTE: Lubricate immerse each synchro ring with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.
(1) Install reverse gear needle bearing up against
shoulder on output shaft (Fig. 50).
Fig.50REVERSEGEARBEARING
1 - REVERSE GEAR BEARING 2 - SHOULDER
21 - 18 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(2) Install reverse gear over needle bearing (Fig.
51).
DR
Fig.51REVERSEGEAR
1 - REVERSE GEAR
(3) Install brass synchro ring on reverse gear (Fig.
52).
Fig.52REVERSEGEARSYNCHRO
1 - REVERSE GEAR 2 - SYNCHRO RING
(4) Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover 6310-1 (Fig. 53).
CAUTION: One side of the hub has shoulders around the hub bore, this side faces the front of the shaft. One side of the sleeve is tapered the tapered side faces the front of the shaft.
(5) Install new fifth-reverse hub snap ring (Fig.
54). Verify snap ring is seated in the groove.
Fig.53FIFTH/REVERSESYNCHROASSEMBLY
1 - SPACER 2 - PRESS RAM 3 - REVERSE GEAR 4 - FIFTH-REVERSE SYNCHRO ASSEMBLY 5 - REMOVER 6310-1
6 - PRESS BLOCKS 7 - OUTPUT SHAFTFig.54FIFTH/REVERSESYNCHROHUBSNAPRING 1 - FIFTH-REVERSE SYNCHRO ASSEMBLY 2 - SNAP RING 3 - PRESS BED 4 - PRESS BLOCKS
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 19
(6) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 55).
(8) Install fifth gear on shaft and onto bearing
(Fig. 57).
Fig.55FIFTHGEARSYNCHRORING
1 - FIFTH-SPEED SYNCHRO RING 2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
1 - FIFTH GEAR 2 - BEARING
Fig.57FIFTHGEAR
(7) Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft (Fig. 56). Verify bearing is properly seated.
(9) Invert output shaft and set the shaft in Collar
6310-1 so fifth gear is seated on the tool (Fig. 58).
(10) Install first gear bearing on output shaft (Fig. 58). Verify bearing is seated on shaft shoulder and is properly joined.
Fig.56FIFTHGEARBEARING
1 - SHAFT SHOULDER 2 - FIFTH GEAR BEARING
Fig.58FIRSTGEAR
1 - FIRST GEAR BEARING 2 - SHAFT SHOULDER 3 - COLLAR 4 - PRESS BLOCKS
21 - 20 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(11) Install first gear on shaft and over bearing
(Fig. 59) with bearing synchro cone facing up.
DR
Fig.59FIRSTGEAR
1 - FIRST GEAR 2 - COLLAR 3 - BEARING
(12) Install first gear synchro ring (Fig. 60).
Fig.61STARTING1-2SYNCHRO
1 - 1-2 SYNCHRO ASSEMBLY 2 - COLLAR 3 - FIRST GEAR SIDE
Fig.60FIRSTGEARSYNCHRORING
1 - FIRST GEAR SYNCHRO RING 2 - COLLAR 3 - FIRST GEAR
(13) Start 1-2 synchro assembly on shaft by hand
(Fig. 61).
CAUTION: One side of the synchro sleeve is marked First Gear Side, this side must face first gear.
(14) Press 1-2 synchro onto output shaft using
suitable size pipe and shop press (Fig. 62).
CAUTION: Keep synchro ring and sleeve aligned as the hub is being pressed onto the shaft. The syn- chro ring can be cracked if it becomes misaligned.
Fig.621-2SYNCHROONOUTPUTSHAFT
1 - PIPE TOOL 2 - SYNCHRO RING 3 - COLLAR 4 - 1-2 SYNCHRO ASSEMBLY 5 - PRESS RAM
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 21
(15) Install interm ring. (16) Install new 1-2 synchro hub snap ring (Fig.
63). Verify snap ring is seated in shaft groove.
(19) Install second gear needle bearing on shaft
(Fig. 65).
Fig.631-2SYNCHROHUBSNAPRING
1 - 1-2 SYNCHRO 2 - COLLAR 3 - SYNCHRO SNAP RING
(17) Install second gear synchro ring in 1-2 syn- chro hub and sleeve (Fig. 64). Verify synchro ring is seated in sleeve.
(18) Install synchro friction cone and synchro cone
in synchro ring.
Fig.65SECONDGEARBEARING
1 - SECOND GEAR BEARING 2 - COLLAR
(20) Install second gear onto shaft and bearing (Fig. 66). Verify second gear is seated on synchro components.
Fig.64SECONDGEARSYNCHRORING
1 - SECOND GEAR SYNCHRO RING 2 - 1-2 SYNCHRO 3 - COLLAR
Fig.66SECONDGEAR
1 - COLLAR 2 - 1-2 SYNCHRO ASSEMBLY 3 - BEARING 4 - SECOND GEAR
21 - 22 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(21) Install two-piece thrust washer with halves seated in the shaft groove and washer lugs seated in shaft lug bores (Fig. 67). Verify i.d. grooves and markings noted during removal are facing the correct direction.
DR
Fig.68RETAININGRING
1 - THRUST WASHER RETAINING RING 2 - THRUST WASHER HALVES 3 - SECOND GEAR 4 - LOCATING DIMPLE
Fig.67TWO-PIECETHRUSTWASHER
1 - WASHER GROOVE IN SHAFT 2 - LUG BORE 3 - THRUST WASHER LUGS 4 - LUG BORE 5 - LUG 6 - WASHER HALF
Fig.69THRUSTRETAINER
1 - PLASTIC MALLET 2 - THRUST WASHER RETAINING RING
(22) Start retaining ring around two-piece thrust washer (Fig. 68). Verify locating dimple is between thrust washer halves.
(23) Seat thrust washer retaining ring with plastic
mallet (Fig. 69).
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 23
(24) Install third gear needle bearing on shaft (Fig.
70).
(26) Install third speed synchro ring on third gear
(Fig. 72).
Fig.70THIRDGEARBEARING
