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1 - THIRD GEAR BEARING
(25) Install third gear on shaft and bearing (Fig.
71).
Fig.72THIRDGEARSYNCHRORING
1 - THIRD SPEED SYNCHRO RING 2 - THIRD GEAR
(27) Start 3-4 synchro hub on output shaft splines
by hand (Fig. 73).
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has grooves in it, this side must faces the front of the shaft.
Fig.71THIRDGEAR
1 - THIRD GEAR 2 - BEARING
Fig.733-4SYNCHROHUBONOUTPUTSHAFT
1 - GROOVED SIDE OF SLEEVE 2 - 3-4 SYNCHRO ASSEMBLY
21 - 24 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(28) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to output shaft as possible but not contacting the shaft splines.
(30) Install output shaft bearing. (31) Install output shaft bearing snap ring with heavy duty snap ring pliers (Fig. 76). Verify snap ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
Fig.76OUTPUTSHAFTBEARINGSNAP
1 - BEARING SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS
(32) Verify position of synchro sleeves before pro- ceeding (Fig. 77). Grooved side of 3-4 sleeve must face forward. First gear side of 1-2 sleeve must face first gear. Tapered side of fifth-reverse sleeve must face forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube. (2) Slide idler gear bearing on shaft (Fig. 78).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 78).
(4) Place first lock ball in dimple at rear end of idler shaft (Fig. 78). Petroleum jelly can be used to hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 79).
(6) Install snap ring in groove at rear of shaft (Fig.
79).
Fig.743-4SYNCHROONOUTPUTSHAFT
1 - PRESS RAM 2 - PIPE TOOL 3 - 3-4 SYNCHRO 4 - THIRD SPEED SYNCHRO RING
(29) Install new 3-4 synchro hub snap ring (Fig.
75). Verify snap ring is seated in groove.
Fig.753-4SYNCHROHUBSNAPRING
1 - 3-4 SYNCHRO HUB SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 25
Fig.77SYNCHROSLEEVELOCATIONS
1 - DOUBLE GROOVE FORWARD 2 - GROOVE FORWARD 3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 4 - TAPER FORWARD
5 - GROOVE FORWARD 6 - 5TH-REV SYNCHRO SLEEVE 7 - 1-2 SYNCHRO SLEEVE 8 - 3-4 SYNCHRO SLEEVE
Fig.78IDLERGEAR&BEARING
1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT
Fig.79IDLERGEARREARTHRUSTWASHER
1 - LOCK BALL 2 - SNAP RING GROOVE 3 - THRUST WASHER
21 - 26 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
(8) Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 80). (9) Install wave washer, flat washer and remain- ing snap ring on idler shaft (Fig. 80). Verify snap ring is seated.
Fig.80IDLERGEAR&SHAFTASSEMBLY
1 - REAR OF SHAFT 2 - GEAR 3 - THRUST WASHER AND BALL 4 - WAVE WASHER 5 - FLAT WASHER 6 - FRONT OF SHAFT 7 - SNAP RING 8 - SNAP RING
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/ BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
replaced as follows:
(2) If necessary, the shift shaft bushing can be
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.
(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.
(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case. (3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case. (4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to a specific depth. The space between the two bush- ings when correctly installed contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
the case.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
DR MANUAL TRANSMISSION - NV3500 (Continued) GEARTRAIN ASSEMBLY
MANUAL TRANSMISSION - NV3500
21 - 27
(4) Install fourth gear synchro ring on input shaft
(Fig. 83).
(1) Install Adapter 6747-1A on input shaft hub of Fixture 6747 (Fig. 81). Then install Adapter 6747-2A on front bearing hub of countershaft. Be sure the shoulder is seated against the countershaft.
Fig.81FIXTUREFORGEARTRAINBUILD-UP
1 - ADAPTER 6747-2A 2 - CUP 8115
3 - ADAPTER 6747-1A 4 - FIXTURE 6747(2) Install input shaft in fixture tool with Adapter Tool
6747-1A positioned under the shaft as shown (Fig. 82). (3) Install pilot bearing in input shaft (Fig. 82).
NOTE: The side of the pilot bearing with the small diameter goes toward the input shaft.
Fig.82PILOTBEARING&INPUTSHAFT
1 - PILOT BEARING 2 - INPUT SHAFT
Fig.83FOURTHGEARSYNCHRO
1 - FOURTH GEAR SYNCHRO RING 2 - INPUT SHAFT
(5) Adjust height of idler gear pedestal on fixture (Fig. 84). Start with a basic height of 18.4 cm (7-1/4
in.). Final adjustment can be made after gear is posi- tioned on pedestal.Fig.84IDLERPEDESTALBASEHEIGHT
1 - REVERSE IDLER PEDESTAL
21 - 28 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(6) Install assembled output shaft and geartrain in input shaft (Fig. 85). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
DR
Fig.86COUNTERSHAFTONFIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig.85OUTPUTSHAFT,GEARTRAIN&INPUT
SHAFT 1 - OUTPUT SHAFT AND GEARTRAIN 2 - INPUT SHAFT 3 - FIXTURE 6747
(7) Install Adapter 6747-2A on front bearing hub of if not previously done. The shoulder
countershaft, goes toward the countershaft.
(8) Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears before pro- ceeding (Fig. 86).
(9) Check alignment of countershaft and output shaft gear teeth. Gears may not align perfectly a dif- ference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This will not interfere with assembly. If difference is greater than this, the coun- tershaft adapter tool is probably upside down.
(10) Position reverse idler in support cup of fixture (Fig. 87). Verify idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out from the geartrain. Adjust pedestal up or down if necessary and verify short end of idler shaft is facing up as shown.
Fig.87REVERSEIDLERASSEMBLYONFIXTURE 1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT 3 - REVERSE IDLER ASSEMBLY 4 - PEDESTAL
DR MANUAL TRANSMISSION - NV3500 (Continued)
(11) On 2-wheel drive transmission, thread one Alignment Pin 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (Fig. 88).
MANUAL TRANSMISSION - NV3500
21 - 29
Fig.88ALIGNOUTPUTSHAFTBEARINGRETAINER 1 - ALIGNMENT PIN 2 - OUTPUT SHAFT BEARING RETAINER
(12) Assemble 1-2 and fifth reverse-shift forks (Fig. 89). Arm of fifth-reverse fork goes through slot in 1-2
fork.Fig.90SHIFTFORKSINSYNCHRO
1 - SYNCHRO SLEEVES 2 - FORK ARMS 3 - SHIFT FORKS
REAR HOUSING - 2WD
NOTE: Transmission shift components must be in Neutral position to prevent damaging the synchro and shift components when installing the housings.
(1) Drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface (Fig. 91).
Fig.891-2&FIFTH-REVERSESHIFTFORKS
1 - 1-2 FORK 2 - 1-2 FORK ARM 3 - FIFTH-REVERSE FORK
(13) Install assembled shift
in synchro sleeves and verify forks are seated in sleeves (Fig. 90).
forks
Fig.91REARHOUSINGDOWELS
1 - HOUSING ALIGNMENT DOWELS 2 - REAR HOUSING 3 - DOWEL FLUSH WITH SURFACE
21 - 30 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 92).
Fig.93COUNTERSHAFTBEARING
1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING
Fig.94REARHOUSING
1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN
(8) Seat rear housing on output shaft rear bearing and countershaft by tapping the housing with a plas- tic mallet.
Fig.92COUNTERSHAFTREARBEARING
1 - COUNTERSHAFT REAR BEARING 2 - REAR BEARING RACE 3 - REAR HOUSING 4 - PETROLEUM JELLY
NOTE: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 93).
(4) Apply extra petroleum jelly to hold counter- shaft rear bearing in place when housing is installed. (5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 93).
(6) Reach into countershaft rear bearing with fin- ger and push each bearing roller outward against the race. Then apply extra petroleum jelly to hold rollers in place during housing installation.
(7) Install rear housing onto geartrain (Fig. 94) and verify bearing retainer pilot stud is in correct bolt hole in housing. Verify countershaft and output shaft bearings are aligned in housing and on counter- shaft.
NOTE: It may be necessary to lift upward on coun- tershaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages the housing.
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 31
(9) Apply Mopar Gasket Maker or equivalent to housing bolt threads, bolt shanks and under bolt heads (Fig. 95).
ADAPTER HOUSING - 4WD
NOTE: Transmission shift components must be in Neutral to prevents damaging to the synchro and shift components when installing the housings.
(1) Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 97).
Fig.95HOUSINGBOLTS
1 - GASKET MAKER 2 - RETAINER AND HOUSING BOLTS 3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK AND THREADS
(10) Start first two bolts in retainer (Fig. 96). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 96).
(12) Tighten retainer bolts to 30-35 N·m (22-26 ft.
lbs.).
Fig.97ADAPTERHOUSING
1 - BEARING RETAINER 2 - RETAINER BOLT 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT BEARING RACE 5 - REAR BEARING
(3) Apply Mopar Gasket Maker or equivalent to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 95).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 93).
Fig.96AlitgnmentPinAndRetainerBolts
1 - BEARING RETAINER BOLT 2 - ALIGNMENT PIN
NOTE: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 93).
(6) Apply extra petroleum jelly to hold counter- shaft rear bearing in place when housing is installed. (7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 93).
21 - 32 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(8) Install adapter housing on geartrain. (9) Install rear bearing snap ring on output shaft
(Fig. 98).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET
(1) Verify all synchro sleeves are in Neutral posi-
tion (centered on hub).
CAUTION: Transmission synchros must all be in Neutral position to prevent damaging the housings, shift forks and gears while installing the housings.
(2) Install 3-4 shift fork in synchro sleeve (Fig. 100). Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.
Fig.98REARBEARINGSNAPRING
1 - SNAP RING PLIERS 2 - SNAP RING 3 - OUTPUT SHAFT
(10) Lubricate lip of new rear seal (Fig. 99) with
Mopar Door Ease, or transmission fluid.
(11) Install new rear seal in adapter housing bore with Installer C-3860-A. Verify seal is seated in hous- ing bore (Fig. 99).
Fig.1003-4SHIFTFORK
1 - 3-4 FORK 2 - ALIGN GROOVES IN FORK ARMS
(3) Slide shift shaft through 3-4 shift fork (Fig.
101).
Fig.99ADAPTERHOUSINGREARSEAL
1 - REAR SEAL 2 - SEAL LIP 3 - OUTPUT SHAFT
Fig.101SHIFTSHAFT
1 - SHIFT SHAFT 2 - 3-4 FORK 3 - SHAFT DETENT NOTCHES
DR MANUAL TRANSMISSION - NV3500 (Continued)
(4) Assemble shift shaft shift lever and bushing (Fig. 102). Verify slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.
MANUAL TRANSMISSION - NV3500
21 - 33
Fig.104SHAFTLEVEROPENING
1 - SHIFT SHAFT
Fig.102SHIFTSHAFTLEVERANDBUSHING
1 - SHAFT LEVER 2 - LEVER BUSHING 3 - BUSHING LOCK PIN SLOT
(5) Install assembled lever and bushing on shift
shaft (Fig. 103).
Fig.105SHIFTSOCKET
1 - SHIFT SOCKET 2 - SHIFT SHAFT
mission will have to be disassembled again to cor- rect shaft alignment.
(9) Select correct new roll pin for shift shaft lever (Fig. 106). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi- mately 33 mm (1-1/4 in.) long.Fig.106ROLLPINIDENTIFICATION
1 - SHAFT LEVER ROLL PIN 2 - SHIFT SOCKET ROLL PIN
Fig.103SHIFTSHAFTLEVERANDBUSHING
1 - SHIFT SHAFT 2 - SHAFT LEVER AND BUSHING 3 - 3-4 FORK
(6) Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (Fig. 104).
(7) Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 105).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Both shaft roll pins can be installed when the shaft is 180° off. If this occurs, the trans-
21 - 34 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)DR
(10) Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 107).
(13) Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 109).
Fig.107SHIFTSHAFTROLLPIN
Fig.109SHIFTSOCKETROLLPIN
1 - SHAFT LEVER ROLL PIN 2 - LEVER AND BUSHING
(11) Seat shaft lever roll pin with pin punch (Fig.
108).
CAUTION: Shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 108).
1 - ROLL PIN 2 - SHIFT SOCKET 3 - SHIFT SHAFT
(14) Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation (Fig. 110).
Fig.108SHIFTSHAFT/LEVERROLLPIN
1 - BUSHING LOCK PIN SLOT 2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig.110SEATSHIFTSOCKET
1 - PIN PUNCH 2 - SHIFT SOCKET 3 - SEAT ROLL PIN FLUSH 4 - SHIFT SOCKET
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 35
(15) Verify that notches in shift fork arms are
aligned (Fig. 111). Realign arms if necessary.
and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.
Fig.111SHIFTLEVERPOSITION
1 - SHIFT FORK ARMS 2 - DETENT BORE
(16) Rotate shift lever and bushing downward to
expose detent bore in the lever.
(17) Install detent spring then the ball into the detent bore (Fig. 112) and hold the ball in the lever. Then rotate the lever upward into the fork arm notches.
NOTE: Verify detent ball is seated in the fork arms before proceeding.
Fig.113INPUTSHAFT&COUNTERSHAFT
BEARING
1 - INPUT SHAFT BEARING 2 - COUNTERSHAFT FRONT BEARING 3 - SHIFT SHAFT BUSHING
(2) Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (Fig. 113). Large diameter side of bearing cage goes toward countershaft (Fig. 114). Small diameter side goes toward bearing race in housing.
(3) Reach into countershaft front bearing with fin- ger and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place during housing installation.
Fig.112DETENTSPRINGANDBALL
1 - SHAFT LEVER 2 - SPRING AND BALL 3 - MAGNET
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
(1) If previously removed, install input shaft bear- ing in front housing bore (Fig. 113). Install snap ring
Fig.114COUNTERSHAFTFRONTBEARING
1 - BEARING RACE 2 - PETROLEUM JELLY 3 - COUNTERSHAFT FRONT BEARING
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
21 - 36 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(5) Apply 1/8 in. wide bead of Mopar Gasket Maker or equivalent to mating surfaces of front and rear housings (Fig. 115).
DR
Fig.116HOUSINGBOLTS
1 - HOUSING BOLTS
(12) Install shift shaft bushing lock bolt (Fig. 117). Apply Mopar Gasket Maker or equivalent to bolt threads, shank and underside of bolt head before installation.
CAUTION: If lock bolt cannot be fully installed the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned.
Fig.115SEALHOUSINGS
1 - HOUSING FLANGE SURFACE 2 -GASKET MAKER
(6) Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.
CAUTION: Front housings will not seat if shift com- ponents are not in Neutral or one or more compo- nents are misaligned. Do not force the front housing into place.
(8) Tap rear housing alignment dowels back into place with hammer and pin punch. Both dowels should be flush fit in each housing. Have helper hold transmission upright while dowels are tapped back into place.
(9) Place transmission in horizontal position. (10) Apply Mopar Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 116).
(11) Install and start housing attaching bolts by hand (Fig. 116). Then tighten bolts to 34 N·m (25 ft. lbs.).
Fig.117SHAFTLOCKBOLT
1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET
shift
(13) Lubricate then install
shaft detent plunger in housing bore. Lubricate plunger with semi-synthetic/synthetic grease. Verify plunger is fully seated in detent notch in shift shaft. (14) Install detent spring inside plunger. (15) Install detent plug in end of Installer 8123. Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore. Drive detent plug into transmission case until plug seats.
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 37
(16) Install backup light switch (Fig. 118).
(19) Apply bead of Mopar silicone sealer or equiv- alent to flange surface of front bearing retainer (Fig. 121).
Fig.118BACKUPLIGHTSWITCH
1 - BACKUP LIGHT SWITCH
(17) Install input shaft snap ring (Fig. 119).
Fig.119SHAFTSNAPRING-TYPICAL
1 - INPUT SHAFT SNAP RING
(18) Install new oil seal in front bearing retainer
with Installer 6448 (Fig. 120).
Fig.121SEALBEARINGRETAINER-TYPICAL
1 - APPLY SEALER BEAD 2 - INPUT SHAFT BEARING RETAINER
(20) Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 122). Verify bolt holes are aligned before seating retainer.
CAUTION: Be sure sealer does not get into the oil feed hole in the transmission case or bearing retainer.
Fig.120BEARINGRETAINEROILSEAL
1 - INSTALLER 2 - FRONT BEARING RETAINER
Fig.122INPUTSHAFTBEARINGRETAINER
1 - INPUT SHAFT 2 - OIL FEED 3 - BEARING RETAINER
21 - 38 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued)(21) Install and tighten bearing retainer bolts to
7-10 N·m (5-7 ft. lbs.) (Fig. 123).
DR
Fig.123BEARINGRETAINERBOLTS-TYPICAL
1 - RETAINER BOLTS 2 - RETAINER
SHIFT TOWER AND LEVER
(1) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(2) Shift the transmission into third gear. (3) Align and install shift tower and lever assem- bly (Fig. 124). Be sure shift ball is seated in socket and the offset in the tower is toward the passenger side of the vehicle before installing tower bolts.
Fig.124SHIFTTOWER
1 - SHIFT TOWER 2 - SHAFT SOCKET 3 - SHIFT BALL
(4) Install shift tower bolts (Fig. 125) and tighten
bolts to 8.5 N·m (75.2 in. lbs.).
(5) Fill transmission to bottom edge of fill plug
hole with lubricant.
(6) Install and tighten fill plug to 34 N·m (25 ft.
lbs.).
Fig.125SHIFTTOWERBOLTS
1 - SHIFT TOWER AND LEVER ASSEMBLY
(7) Check transmission vent. Be sure vent is open
and not restricted.
INSTALLATION
NOTE: If a new transmission is being installed, use all components supplied with the new transmission. For example, if a new shift tower is supplied, do not re-use the original shift tower.
(1) Clean transmission front housing mounting
surface.
(2) Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces (Fig. 126) of following components:
† release fork ball stud. † release bearing slide surface. † input shaft splines. † release bearing bore. † propeller shaft slip yoke. (3) Support and secure transmission to jack. (4) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(5) Verify front housing is fully seated. Install transmission bolts without washers and tighten bolts into the engine to 41 N·m (30 ft. lbs.). Tighten the bolts with washers into the transmission to 68 N·m (50 ft. lbs.) (Fig. 127).
(6) Install rear crossmember and tighten nuts to
102 N·m (75 ft. lbs.).
(7) Install transmission rear mounting bolts and
tighten to 68 N·m (50 ft. lbs.). (8) Install front dust shield. (9) Install structural dust cover and tighten the
bolts to 73 N·m (54 ft. lbs.). (10) Install starter motor. (11) Install suspension crossmember and tighten
nuts to 102 N·m (75 ft. lbs.).
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 39
Fig.126LUBRICATIONPOINTS
Fig.127TRANSMISSION
1 - RELEASE FORK 2 - FORK BALL STUD 3 - BEARING SLIDE SURFACE 4 - SPLINE 5 - RELEASE BEAING
(12) Connect transmission harnesses to clips on
marks aligned.
case and connect switches.
(13) Install slave cylinder and tighten cylinder
nuts to 23 N·m (200 in. lbs.).
(14) Install transfer case and transfer case linkage
if equipped.
1 - BOLT WITHOUT WASHER 2 - BOLT WITH WASHER
(15) Remove transmission jack. (16) Install propeller shaft/shafts with reference
(17) Install exhaust on the exhaust manifolds. (18) Fill transmission with lubricant. Correct fill
level is to bottom edge of fill plug hole.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
Crossmember Nuts
Transmission Mount Bolts
4WD
Transmission Mount Bolts
2WD
Structural Dust Cover Bolts
Drain/Fill Plug
Front To Rear Housing Bolts Front Bearing Retainer Bolts
Idler Shaft Bolts
Rear Bearing Retainer Bolts
Shift Tower Bolts
Slave Cylinder Nuts Transfer Case Nuts
N·m 102
68
68
73
9-27
30-35
7-10
19-25
30-35
7-10
23
47Ft. Lbs.
In. Lbs.
75
50
50
54
14-20
22-26
5-7
14-18
22-26
5-7
17
3562-88
62-88
21 - 40 MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500 (Continued) SPECIAL TOOLSDR
REMOVERC-3985-B
INSTALLERC-3972-A
REMOVER6957
INSTALLER6951
HANDLEC-4171
REMOVER/INSTALLER6858
FIXTURE6747
ADAPTER6747-1A
ADAPTER6747-2A
DR MANUAL TRANSMISSION - NV3500 (Continued)
MANUAL TRANSMISSION - NV3500
21 - 41
CUP8115
ALIGNMENTSTUD8120
BEARINGSPLITTER1130
INSTALLERC-3860-A
TUBE6310-1
INSTALLER8123
INSTALLER8118
INSTALLER64428
REMOVER/INSTALLER8119
REMOVER8117A
21 - 42 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500
TABLE OF CONTENTS
page
DR
page
MANUAL TRANSMISSION - NV4500
ADAPTER HOUSING SEAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 44
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 79
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 79REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83SHIFT MECHANISM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85SHIFT COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86MANUAL TRANSMISSION - NV4500
DESCRIPTIONThe NV4500 is a five speed constant mesh manual transmission. All gear ranges including reverse are synchronized. Fifth gear is an overdrive range. The transmission has a cast iron gear case and aluminum shift cover.
Two versions are used, a standard duty for 5.7L applications and a heavy duty for V10 and Cummins diesel applications. Main difference is a larger diam- eter input shaft, for the heavy duty model.
Tapered roller bearings support the drive gear, mainshaft and countershaft in the gear case. Roller bearings in the drive gear support the forward end of the mainshaft. The mainshaft gears are all supported on caged type roller bearings. Drive gear thrust reac- tion is controlled by a needle type thrust bearing. The bearing is located at the forward end of the mainshaft.
The transmission is a top loader style. The shift lever is located in a shifter tower which is bolted to the shift cover and operates the shift forks and rails directly. The shift forks and rails are all located within the aluminum cover which is bolted to the top of the gear case.
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 1).
The tag provides the transmission model number, build date and part number. Be sure to reinstall the I.D. tag if removed during service. The information on the tag is essential to correct parts ordering.
Fig.1IDENTIFICATIONTAGLOCATION
1 - PTO COVER 2 - I.D. TAG
OPERATION
The manual transmission receives power through the clutch assembly from the engine. The clutch disc is splined to the transmission input shaft and is turned at engine speed at all times that the clutch is engaged. The input shaft is connected to the trans- mission countershaft through the mesh of fourth speed gear on the input shaft and the fourth counter- shaft gear. At this point all the transmission gears are spinning.
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 43
noise, excessive wear, internal bind and hard shift- ing. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indi- cations of component damage are usually hard shift- ing and noise.
Component damage, incorrect clutch adjustment or damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Incorrect adjustment or a worn/damaged pressure plate or disc can cause incorrect release. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur- ing normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds. Severe highly audible transmission noise is generally the initial indicator of a lubricant problem. improper or contaminated lubricant will promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear breakage.
Insufficient,
REMOVAL
(1) Shift transmission into Neutral. (2) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(3) Remove shift lever extension from shift tower
and lever assembly.
(4) Remove shift tower bolts (Fig. 2).
The driver selects a particular gear by moving the shift lever to the desired gear position. This move- ment moves the internal transmission shift compo- nents to begin the shift sequence. As the shift lever moves the selected shift rail, the shift fork attached to that rail begins to move. The fork is positioned in a groove in the outer circumference of the synchro- nizer sleeve. As the shift fork moves the synchronizer sleeve, the synchronizer begins to speed-up or slow down the selected gear (depending on whether the driver is up-shifting or down-shifting). The synchro- nizer does this by having the synchronizer hub splined to the mainshaft, or the countershaft in some cases, and moving the blocker ring into contact with the gear’s friction cone. As the blocker ring and fric- tion cone come together, the gear speed is brought up or down to the speed of the synchronizer. As the two speeds match, the splines on the inside of the syn- chronizer sleeve become aligned with the teeth on the blocker ring and the friction cone and eventually will slide over the teeth, locking the gear to the mainshaft, or countershaft, through the synchronizer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or an incor- rect lubricant level check. A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a minute or so before checking. These recommendations will ensure an accurate check and avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition.
Leaks can occur at the mating surfaces of the gear case, adaptor or extension housing, or from the front/ rear seals. A suspected leak could also be the result of an overfill condition. Leaks at the rear of the extension or adapter housing will be from the hous- ing oil seals. Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening or use of a non-recommended sealer. A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may be seen drip- ping from the clutch housing after extended opera- tion. If the leak is severe, it may also contaminate the clutch disc causing the disc to slip, grab and or chatter.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant level, improper or contaminated lubricants. The con- sequence of using non-recommended lubricants is
1 - SHIFT TOWER 2 - SHIFTER 3 - BOLTS
Fig.2SHIFTTOWER
21 - 44 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(5) Remove shift tower and isolator plate from
transmission shift cover.
(6) Raise and support vehicle. (7) Remove skid plate, if equipped. (8) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(9) Remove exhaust system Y-pipe. (10) Disconnect speed sensor and backup light
switch connectors.
block.
(11) Support engine with safety stand and a wood
(12) If transmission is to be disassembled, remove drain bolt at bottom of PTO cover and drain lubri- cant (Fig. 3).
Fig.3FILLANDDRAINPLUGS
1 - PTO COVER 2 - DRAIN BOLT 3 - FILL PLUG
TWO WHEEL DRIVE
(1) Remove bolts attaching transmission to rear
crossmember mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmenber.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
Fig.4TRANSFERCASESHIFTER-TYPICAL
1 - TRANSMISSION 2 - TRANSFER CASE SHIFT MECHANISM
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts. (4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove
bolts/nuts
attaching
transmission
mount to rear crossmember.
(9) Remove rear crossmember bolts and pry out
crossmenber.
equipped.
(10) Remove clutch slave cylinder splash shield, if
(11) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
NOTE: The hydraulic linkage has a quick connect at the slave cylinder. This fitting should not be discon- nected.
NOTE: The hydraulic linkage has a quick connect at the slave cylinder. This fitting should not be discon- nected.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts. (7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans- fer case range lever. Then remove transfer case shift mechanism from transmission (Fig. 4).
(12) Remove transmission to clutch housing bolts. (13) Slide transmission and jack rearward until
input shaft clears clutch housing.
(14) Lower transmission jack and remove trans-
mission from under vehicle.
DISASSEMBLY
SHIFT MECHANISM
(1) Remove bolts holding shift tower to shift mech-
anism cover and remove tower.
DR MANUAL TRANSMISSION - NV4500 (Continued)
(2) Remove bolts (Fig. 5) holding shift mechanism
cover to transmission.
MANUAL TRANSMISSION - NV4500
21 - 45
Fig.7SHIFTMECHANISMCOVER
1 - SHIFT MECHANISM COVER 2 - ALIGNMENT DOWELS
Fig.5SHIFTMECHANISMCOVERBOLTS
EXTENSION/ADAPTER HOUSING
1 - SHIFT MECHANISM COVER 2 - BOLTS
(1) Remove bolts attaching extension/adapter hous-
ing to gear case (Fig. 8).
(3) Pry up shift mechanism cover at slot (Fig. 6) in
cover.
Fig.6LOOSENSHIFTMECHANISM
1 - SHIFT MECHANISM COVER SLOT 2 - PRY TOOL
(4) Raise mechanism up enough to disengage it
from the dowl pins (Fig. 7).
(5) Raise front of the mechanism and lift up and
off the transmission.
Fig.8EXTENSION/ADAPTERHOUSINGBOLTS
1 - EXTENSION HOUSING 2 - BOLTS (8)
21 - 46 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(2) Remove extension/adapter housing (Fig. 9). There is one alignment dowel in the gear case and one in the extension/adapter housing.
NOTE: Wedge breaker bar handle against workbench. Purpose of socket wrench and breaker bar is to pre- vent mainshaft from turning while nut is loosened.
(5) Remove fifth gear nut, then remove belleville
washer from mainshaft.
Fig.9EXTENSION/ADAPTERHOUSING
1 - GEAR CASE 2 - EXTENSION HOUSING
(3) Remove rubber spline seal from end of main- shaft (Fig. 10). The seal is used to prevent lubricant loss during shipping and does not have to be replaced if damaged.
Fig.10MAINSHAFTSPLINESEAL
1 - MAINSHAFT 2 - RUBBER SPLINE SEAL
FIFTH GEAR NUT
Fig.11FIFTHGEARNUT
1 - WRENCH 2 - FIFTH GEAR NUT 3 - SPLINE SOCKET
FIFTH GEAR
(1) Remove fifth gear shift fork roll pins (Fig. 12).
Drive roll pins out from the bottom of fork.
(1) Remove extension/adapter housing. (2) Loosen fifth gear clamp nut clamping screw
approximately 1 1/2 turns.
(3) Install Wrench 6743 on fifth gear nut (Fig. 11).
NOTE: Wrench only fits one way on nut. Make sure wrench is fully engaged in nut slots and is not cocked.
(4) Install Socket 6993 4X2 or Socket 6984 4X4 with breaker bar to hold mainshaft and remove fifth gear nut.
Fig.12FIFTHGEARSHIFTFORKROLLPINS
1 - ROLL PINS 2 - FIFTH GEAR SHIFT FORK
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 47
(2) Remove fifth gear clutch hub and gear snap
ring from countershaft (Fig. 13).
(3) Remove countershaft fifth gear clutch gear and
stop ring.
(4) Tap off fifth gear shift fork and gear assembly
off rail with plastic mallet.
(5) Remove fifth gear shift fork from sleeve. (6) Remove sleeve, struts and strut springs from
countershaft fifth gear hub, if necessary.
(8) Remove
coned shape
rear bearing thrust
washer from countershaft (Fig. 15).
NOTE: Note washer bore locating notch for assem- bly reference.
(9) Remove thrust washer locating pin from coun-
tershaft.
Fig.13FIFTHGEARCLUTCHGEARSNAPRING
1 - CLUTCH GEAR RING 2 - FIFTH SYNCHRO CLUTCH GEAR
(7) Remove countershaft fifth gear needle bearing
assembly (Fig. 14).
Fig.15COUNTERSHAFTREARBEARINGTHRUST
WASHER
1 - THRUST WASHER 2 - THRUST WASHER PIN
(10) Remove mainshaft fifth gear with Puller Set 6444 and Jaw 6459 or 6820. Position first Jaw on gear (Fig. 16).
Fig.14COUNTERSHAFTFIFTHGEARNEEDLE
BEARING
1 - NEEDLE BEARING 2 - COUNTERSHAFT
Fig.16JAWONMAINSHAFTFIFTHGEAR
1 - MAINSHAFT FIFTH GEAR 2 - JAW 3 - MAINSHAFT
21 - 48 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(11) Assemble Puller Flange 6444-1and Puller Rods 6444-3 4X2 or 6444-4 4X4 (Fig. 17). Slide assembly onto output shaft and seat flange in notch of jaw.
(13) Install Puller and Bolt 6444 on puller rods and secure puller to rods with retaining nuts (Fig. 19). Tighten puller bolt to remove gear from shaft splines.
Fig.17PULLERFLANGE
1 - JAW 2 - PULLER FLANGE
(12) Position second puller jaw on gear and in notch of puller flange (Fig. 18). Slide Collar 6444-8
over puller jaws to hold them in place.Fig.19PULLERASSEMBLY
1 - COLLAR 2 - JAWS 3 - BOLT 4 - WRENCH 5 - MAINSHAFT 6 - PULLER FLANGE
(14) Remove mainshaft rear bearing plate bolts and remove fifth gear plate end play shims and bear- ing cup (Fig. 20).
Fig.18PULLERCOLLAR
1 - JAWS 2 - COLLAR
Fig.20FIFTHGEARBEARINGPLATE,SHIMSAND
BEARINGCUP
1 - MAINSHAFT REAR BEARING CUP 2 - BEARING SHIMS 3 - BEARING PLATE 4 - FIFTH GEAR
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 49
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 21).
CAUTION: Do not reuse retainer bolts.
(4) Remove front retainer bearing cup with Puller 6444. Assemble Puller Flange 6444-1 and Puller Rods 6444-4 (Fig. 23). Insert Jaws 6453-1 in puller flange. Narrow lip of puller jaws will go under bearing cup.
Fig.21FRONTBEARINGRETAINER
1 - DRIVE GEAR 2 - FRONT BEARING RETAINER
(2) Lightly tap retainer back and forth with plastic
mallet to work it out of gear case.
NOTE: Retainer flange extends into transmission case and is a snug fit.
(3) Remove front retainer seal by (Fig. 22) collaps-
ing one side of seal then prying it out.
Fig.23PULLERRODS,FLANGEANDJAWS
1 - RODS 2 - FLANGE 3 - JAWS
(5) Install Disc C-4487-1 into bearing retainer for
Insert 6453-2 to rest upon.
(6) Install assembled tools in front retainer (Fig. 24) with puller jaws seated under bearing cup. Place Insert 6453-2 in center of puller jaws, to hold puller jaws in place.
Fig.22BEARINGRETAINERSEAL
1 - SEAL 2 - FRONT BEARING RETAINER
Fig.24INSERTANDRETAINER
1 - INSERT 2 - FRONT RETAINER 3 - JAWS
21 - 50 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(7) Install Puller 6444 on puller rods (Fig. 25) and install retaining nuts on puller rods. Tighten puller bolt to draw bearing cup out of retainer.
DR
Fig.26DRIVEGEAR
1 - MAINSHAFT 2 - DRIVE GEAR
Fig.25BEARINGCUPPULLERASSEMBLY
1 - WRENCH 2 - INSERT 3 - FRONT RETAINER 4 - PULLER 5 - WRENCH
DRIVE GEAR
(1) Remove drive gear (Fig. 26). (2) Remove pilot bearing from drive gear (Fig. 27). (3) Remove tapered bearing from drive gear with Puller Flange 6444-1 and Puller Rods 6444-6 (Fig. 28).
(4) Position first Jaw 6447 on bearing. Slide assembled puller flange and rod tools onto input shaft. Then seat flange in notch of puller jaw.
(5) Position second Jaw 6447 on gear and in notch of puller flange. Slide Collar 6444-8 over puller jaws to hold them in place.
(6) Install Puller 6444 on puller rods then install retaining nuts. Tighten puller bolt to remove bearing cone from drive gear.
MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral. (2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 29).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 30). (4) Roll gear case onto left side.
Fig.27PILOTBEARING
1 - DRIVE GEAR 2 - MAINSHAFT PILOT BEARING
(5) Remove mainshaft assembly (Fig. 31) by lifting front end of mainshaft slightly. Then grasp mainshaft rear splines and turn spline end of mainshaft coun- terclockwise to rotate shaft and geartrain out of case. Tilt mainshaft outward and removed from case.
NOTE: Handling mainshaft carefully because gears are lose on the mainshaft.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
32).
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 51
Fig.30FOURTHGEARCLUTCHGEARSTOPRING 1 - FOURTH GEAR SYNCHRO STOP RING 2 - FOURTH SPEED CLUTCH GEAR
Fig.28FRONTBEARINGPULLER
1 - PULLER 2 - RODS 3 - JAWS 4 - COLLAR 5 - FLANGE 6 - DRIVE GEAR
Fig.31MAINSHAFTANDGEARTRAIN
1 - MAINSHAFT AND CASE
Fig.29DRIVEGEARTHRUSTBEARING
1 - MAINSHAFT 2 - DRIVE GEAR THRUST BEARING
Fig.32COUNTERSHAFTREARBEARINGPLATE 1 - REAR BEARING PLATE 2 - COUNTERSHAFT
21 - 52 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33).
DR
Fig.33ENDPLAYSHIMANDREARBEARINGCUP 1 - COUNTERSHAFT REAR BEARING CUP 2 - END PLAY SHIM
(3) Remove reverse idler shaft (Fig. 34).
Fig.35IDLERGEARANDCOUNTERSHAFT
1 - REVERSE IDLER GEAR 2 - COUNTERSHAFT
Fig.36REVERSEIDLERGEAR
1 - REVERSE IDLER GEAR 2 - DRIVE GEAR BORE
Fig.37IDLERGEARCOMPONENTS
1 - BEARINGS 2 - REVERSE IDLER GEAR
Fig.34REVERSEIDLERSHAFT
1 - REVERSE IDLER SHAFT
(4) Rotate countershaft outward and push reverse idler gear away from countershaft and toward front of case (Fig. 35).
(5) Remove idler gear (Fig. 36). (6) Keep reverse idler gear bearings and spacer together (Fig. 37). Insert idler shaft through gear and bearings to keep them in place.
(7) Remove idler gear thrust washers from gear case. Install washers on idler shaft to keep them together for cleaning and inspection.
DR MANUAL TRANSMISSION - NV4500 (Continued)
(8) Remove countershaft rear bearing with Puller
Flange 6444-1 and Puller Rods 6444-4 (Fig. 38).
NOTE: Shaft cannot be removed from case until rear bearing has been removed.
MANUAL TRANSMISSION - NV4500
21 - 53
(9) Position first Jaw 6449 on bearing cone and
seat puller flange in notch of puller.
(10) Install second Jaw 6449 on bearing and in notch of puller flange. Slide Collar 6444-8 over puller jaws to hold them in place.
NOTE: Retaining collar has small and only fits one way over jaws.
lip on one end
(11) Install Puller 6444 on puller rods, then secure puller to rods with retaining nuts.Tighten puller bolt to remove bearing from shaft.
NOTE: If bearing is exceptionally tight, tap end of puller bolt with copper mallet to help loosen bear- ing.
Fig.39COUNTERSHAFTANDCASE
1 - COUNTERSHAFT
NOTE: Retaining collar has small and only fits one way over jaws.
lip on one end
(16) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts. Tighten puller bolt to remove bearing from shaft.NOTE: If bearing is exceptionally tight, tap end of puller bolt with mallet to help loosen bearing.
Fig.38COUNTERSHAFTREARBEARING
1 - COLLAR 2 - JAWS 3 - PULLER 4 - WRENCH
(12) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 39).
(13) Remove
front bearing, with Puller Flange 6444-1 and Puller Bolts 6444-4 (Fig. 40).
countershaft
(14) Position first Jaw 6451 on bearing and seat
puller flange in notch of puller jaw.
(15) Install second Jaw 6451 on bearing and in notch of puller flange. Slide Collar 6444-8 over puller jaws to hold them in place.
Fig.40CountershaftFrontBearing
1 - JAWS 2 - COLLAR 3 - PULLER 4 - FLANGE
(17) Remove bearing puller tools.
21 - 54 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 41).
DR
Fig.41COUNTERSHAFTFRONTBEARINGCAP
1 - HAMMER 2 - BEARING CAP
(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 42).
Fig.42COUNTERSHAFTFRONTBEARINGCUP
1 - REMOVER 2 - HANDLE
(3) Remove roll pin that secures shift lug on shift rail in case (Fig. 43). A small pin punch can be mod- ified by putting a slight bend in it to drive pin com- pletely out of shift rail (Fig. 43).
(4) Remove shift lug rail.
Fig.43SHIFTLUGROLLPIN
1 - PUNCH 2 - 30° BEND 3 - PIN PUNCH MODIFICATION 4 - SHIFT LUG 5 - SHIFT RAIL
MAINSHAFT
NOTE: Gear and synchro components can be installed backwards. Paint or scribe gear and syn- chro components for installation reference. Then stack geartrain parts in order of removal.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Place 3-4 gear in a press with support under 3rd gear and Remove 3-4 synchro hub, third gear stop ring and third gear as an assembly (Fig. 44).
(3) Remove third gear bearing from mainshaft
(Fig. 45).
(4) Remove third gear bearing spacer (Fig. 46). (5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 46).
(6) Remove second gear thrust washer (Fig. 47).
Note washer notch for locating pin.
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 55
Fig.46SNAPRINGANDTHIRDGEARBEARING
SPACER 1 - SECOND GEAR THRUST WASHER 2 - THRUST WASHER SNAP RING 3 - THIRD GEAR BEARING SPACER
Fig.47SECONDGEARTHRUSTWASHER
1 - SECOND GEAR 2 - THRUST WASHER 3 - SECOND GEAR BEARING
Fig.44THIRDGEAR,STOPRING,AND3-4HUB
1 - THIRD GEAR 2 - THIRD GEAR STOP RING 3 - 3-4 SYNCHRO HUB
Fig.45THIRDGEARBEARING
1 - THIRD GEAR NEEDLE BEARING
21 - 56 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)DR
(7) Remove thrust washer locating pin (Fig. 48)
with needle nose pliers.
(9) Remove second gear bearing (Fig. 50).
Fig.48THRUSTWASHERLOCATINGPIN
1 - THRUST WASHER LOCATING PIN
(8) Remove second gear (Fig. 49).
Fig.50SECONDGEARBEARING
1 - SECOND GEAR NEEDLE BEARING
(10) Remove second gear clutch cone snap ring
from mainshaft synchro hub groove (Fig. 51).
Fig.49SECONDGEAR
1 - SECOND GEAR
Fig.51SECONDGEARCLUTCHCONESNAPRING 1 - 1-2 SLEEVE 2 - SNAP RING 3 - SECOND GEAR CLUTCH CONE
DR MANUAL TRANSMISSION - NV4500 (Continued)
(11) Remove second gear clutch cone, synchro
clutch ring and synchro stop ring (Fig. 52).
MANUAL TRANSMISSION - NV4500
21 - 57
Fig.541-2SYNCHROSLEEVEANDHUB
1 - 1-2 SLEEVE AND HUB
Fig.52SECONDGEARCLUTCHCONEANDRING 1 - 1-2 SLEEVE AND HUB 2 - SYNCHRO STOP RING 3 - CLUTCH RING 4 - SECOND GEAR CLUTCH CONE
(12) Remove 1-2 synchro hub snap ring (Fig. 53).
Fig.531-2SLEEVEANDHUBSNAPRING
1 - 1-2 HUB SNAP RING 2 - 1-2 SLEEVE AND HUB
(13) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 54).
NOTE: Tapered side of sleeve also goes toward front. Do not disassemble synchro components unless worn or damaged.
(14) Remove first gear synchro stop ring and
clutch ring (Fig. 55).
(15) Remove first gear clutch cone front snap ring
from mainshaft hub (Fig. 56).
Fig.55FIRSTGEARSTOPANDCLUTCHRING
1 - FIRST GEAR CLUTCH RING 2 - FIRST GEAR STOP RING
Fig.56FIRSTGEARCLUTCHGEARFRONTSNAP
RING
1 - FIRST SPEED CLUTCH GEAR 2 - CLUTCH GEAR SNAP RING (FRONT)
21 - 58 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(16) Remove first gear clutch cone (Fig. 57). (17) Remove first gear clutch gear rear snap ring
from mainshaft hub (Fig. 57).
NOTE: Do not remove this snap ring unless main- shaft is being replaced.
DR
(18) Remove mainshaft rear bearing, with Puller Flange 6444-1 and Puller Rods 6444-3 for 4X2 or 6444-4 for 4X4.
(19) Position the first Jaw 6445 on the bearing cone and seat Puller Flange 6444-1 in notch of jaw (Fig. 58).
(20) Install second Jaw 6445 on the bearing cone and puller flange. Slide Collar 6444-8 over jaws to hold them in place.
Fig.57FIRSTGEARCLUTCHGEAR
1 - CLUTCH GEAR SNAP RING (REAR) 2 - FIRST SPEED CLUTCH GEAR
1 - REAR BEARING 2 - FLANGE 3 - JAW 4 - COLLAR
Fig.58MAINSHAFTREARBEARINGPULLER
5 - MAINSHAFT 6 - PULLER 7 - RODS 8 - JAW
DR MANUAL TRANSMISSION - NV4500 (Continued)
MANUAL TRANSMISSION - NV4500
21 - 59
(21) Install Puller 6444 on the puller rods and secure with nuts (Fig. 59). Tighten puller bolt to the remove bearing.
(22) Remove bearing puller tools and rear main-
shaft bearing from output shaft.
CAUTION: Do not disassemble synchro compo- nents unless they are damaged. If synchro sleeve or struts require service, mark position of sleeve on hub before removal. Correct sleeve position is important as sleeve can be installed backwards causing shift problems.
(25) Remove reverse gear bearing assembly from
mainshaft (Fig. 61).
Fig.59MAINSHAFTREARBEARING
Fig.61REVERSEGEAR,BEARING,ANDSTOP
RING
1 - JAWS 2 - COLLAR 3 - FLANGE 4 - MAINSHAFT 5 - PULLER 6 - TIGHTENING WRENCH 7 - HOLDING WRENCH 8 - RODS
(23) Remove reverse gear thrust washer (Fig. 60).
1 - FIRST GEAR 2 - REVERSE GEAR ASSEMBLY 3 - BEARING ASSEMBLY 4 - STOP RING
(26) Remove reverse gear bearing spacer from
mainshaft (Fig. 62).
(27) Remove reverse clutch gear snap ring (Fig. 62). Heavy duty snap ring pliers will be required to spread the ring far enough to remove it.
Fig.60REVERSEGEARTHRUSTWASHER
1 - REVERSE GEAR 2 - THRUST WASHER
(24) Remove reverse gear and synchro components
as assembly (Fig. 61).
Fig.62REVERSEGEARBEARINGSPACERAND
FIRSTGEARSNAPRING
1 - CLUTCH GEAR SNAP RING 2 - REVERSE GEAR BEARING SPACER
21 - 60 MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV4500 (Continued)(28) Remove reverse clutch gear (Fig. 63).
DR
Fig.63ReverseClutchGear
1 - REVERSE CLUTCH GEAR
(29) Remove first gear from bearing and mainshaft
(Fig. 64).
Fig.64FIRSTGEAR
1 - FIRST GEAR
(30) Remove first gear bearing from mainshaft
(Fig. 65).
CLEANING
Clean the gears, shafts, shift components and transmission housings with a standard parts clean- ing solvent. Do not use acid or corrosive base sol- vents. Dry all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk or similar sol- vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
Fig.65FIRSTGEARBEARING
1 - MAINSHAFT 2 - FIRST GEAR BEARING
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and polished out with crocus cloth.
Inspect the reverse idler gear, bearings, shaft and thrust washers. Replace the bearings if the rollers are worn, chipped, cracked, flat-spotted or brinnelled. Replace the gear if the teeth are chipped, cracked or worn thin.
Inspect the front bearing retainer and bearing cup. Replace the bearing cup if scored, cracked, brinnelled or rough. Check the release bearing slide surface of the retainer carefully. Replace the retainer if worn or damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap ring grooves and threads. Replace the shaft if any surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the shaft if any surfaces exhibit considerable wear or damage.
Inspect shift forks for wear and distortion. Check fit of the sleeve in the fork to be sure the two parts fit and work smoothly. Replace the fork if the roll pin
