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TRANSMISSION TABLE OF CONTENTS page
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AX15 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1
NV1500 TRANSMISSION . . . . . . . . . . . . . . . . . . . 44
AX15 MANUAL TRANSMISSION TABLE OF CONTENTS page DESCRIPTION AND OPERATION AX15 MANUAL TRANSMISSION . . . . . . . . . TRANSMISSION IDENTIFICATION . . . . . . . . TRANSMISSION SHIFT PATTERN . . . . . . . . RECOMMENDED LUBRICANT . . . . . . . . . . . TRANSMISSION SWITCH AND PLUG LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION GEAR RATIOS. . . . . . . . . . TRANSMISSION ASSEMBLY INFORMATION DIAGNOSIS AND TESTING AX15 INITIAL DIAGNOSIS . . . . . . . . . . . . . . LOW LUBRICANT LEVEL. . . . . . . . . . . . . . . HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . TRANSMISSION NOISE . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION TRANSMISSION . . . . . . . . . . . . . . . . . . . . .
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DESCRIPTION AND OPERATION AX15 MANUAL TRANSMISSION Vehicles equipped with the 2.5L turbo diesel engine and manual transmission utilize the AX15. The AX15 is a 5–speed, synchromesh, manual transmission. Fifth gear is an overdrive range with a ratio of 0.79:1. The shift mechanism is integral and mounted in the shift tower portion of the adapter housing (Fig. 1).
TRANSMISSION IDENTIFICATION The AX15 identification code numbers are on the bottom surface of the intermediate plate (Fig. 2).
page FRONT BEARING RETAINER SEAL . . . . . . . . . . . . 9 EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . . 9 DISASSEMBLY AND ASSEMBLY ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER . . . . . . . . . . . . . . 10 SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 18 COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . 33 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 34 CLEANING AND INSPECTION AX15 MANUAL TRANSMISSION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 40 SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SPECIAL TOOLS AX15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 The first number is year of manufacture. The second and third numbers indicate month of manufacture. The next series of numbers is the transmission serial number.
TRANSMISSION SHIFT PATTERN The AX15 shift pattern is shown in (Fig. 3). First and second and third and fourth gear ranges are in line for improved shifting. Fifth and reverse gear ranges are also in line at the extreme right of the pattern (Fig. 3). The AX15 is equipped with a reverse lockout mechanism. The shift lever must be moved through the Neutral detent before making a shift to reverse.
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DESCRIPTION AND OPERATION (Continued)
Fig. 1 AX15 Manual Transmission
Fig. 3 AX15 Shift Pattern Fig. 2 Identification Code Number Location 1 – INTERMEDIATE PLATE 2 – I.D. CODE LOCATION
RECOMMENDED LUBRICANT Recommended lubricant for AX15 transmissions is Mopart 75W–90, API Grade GL–3 gear lubricant, or equivalent. Correct lubricant level is from the bottom edge, to no more than 6 mm (1/4 in.) below the bottom edge of the fill plug hole.
The fill plug is located on the driver’s side of the transmission case (Fig. 4). The drain plug is located on the passenger side of the transmission case near the bottom (Fig. 5). Approximate dry fill lubricant capacity is: • 3.15 liters (3.32 qts.) for 2–wheel drive applications.
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DESCRIPTION AND OPERATION (Continued)
Fig. 4 Fill Plug Location 1 – GEAR CASE 2 – FILL PLUG
Fig. 6 Fill Plug Location 1 – GEAR CASE 2 – FILL PLUG
Fig. 5 Drain Plug Location 1 – GEAR CASE 2 – BACKUP LIGHT SWITCH 3 – DRAIN PLUG
TRANSMISSION SWITCH AND PLUG LOCATIONS The fill plug is at the driver side of the gear case (Fig. 6). The drain plug and backup light switch are on the passenger side of the gear case (Fig. 7).
TRANSMISSION GEAR RATIOS Gear ratios for the AX15 manual transmission are as follows: • First gear: 3.83:1 • Second gear: 2.33:1 • Third gear: 1.44:1 • Fourth gear: 1.00:1 • Fifth gear: 0.79:1 • Reverse: 4.22:1
Fig. 7 Drain Plug/Backup Light Switch Location 1 – GEAR CASE 2 – BACKUP LIGHT SWITCH 3 – DRAIN PLUG
TRANSMISSION ASSEMBLY INFORMATION Lubricate the transmission components with Mopart 75W–90, GL 3 gear lubricant during assembly. Use petroleum jelly to lubricate seal lips and/or hold parts in place during installation. Refer to (Fig. 8) during assembly for AX15 gear assembly identification.
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DIAGNOSIS AND TESTING (Continued)
Fig. 8 Output Shaft and Gears 1 – SNAP RING (SELECTIVE) 2 – 3–4 HUB 3 – INSERT SPRING 4 – 3–4 SLEEVE 5 – SYNCHRO RING 6 – THIRD GEAR 7 – NEEDLE BEARING 8 – OUTPUT SHAFT (2WD) 9 – FIRST/REVERSE HUB 10 – FIRST GEAR 11 – NEEDLE BEARING 12 – PIN 13 – REAR BEARING 14 – SNAP RING (SELECTIVE) 15 – FIFTH GEAR
DIAGNOSIS AND TESTING AX15 INITIAL DIAGNOSIS If a AX15 transmission problem is suspected, follow the steps below in order. • Verify correct lubricant level. Add if necessary. • Check lubricant for overheated or improper fluid. Replace if necessary. • Verify proper operation of the clutch assembly. Refer to the CLUTCH section of the service manual. • If problem persists it will be necessary to remove the transmission from the vehicle and perform one or more of the repair procedures called out in this group of the service manual.
16 17 18 19 20 21 22 23 24 25 26 27 28 29
– – – – – – – – – – – – – –
THRUST WASHER FIRST GEAR SPACER SYNCHRO RING SNAP RING (SELECTIVE) INSERT SPRING INSERT (3) INSERT SPRING SYNCHRO RING NEEDLE BEARING SECOND GEAR REVERSE GEAR AND 1–2 SLEEVE OUTPUT SHAFT (4WD) INSERT (3) INSERT SPRING
LOW LUBRICANT LEVEL A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an incorrect lubricant level check. Leaks can occur at the mating surfaces of the gear case, intermediate plate and 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 housing 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.
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DIAGNOSIS AND TESTING (Continued) 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 causing 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 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.
REMOVAL AND INSTALLATION TRANSMISSION REMOVAL (1) Disconnect the negative battery cable.
HARD SHIFTING Hard shifting is usually caused by a low lubricant level, improper, or contaminated lubricants. The consequence of using non–recommended lubricants is noise, excessive wear, internal bind, and hard shifting. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise. Component damage, incorrect clutch adjustment, or a 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 the 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 during 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. 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 breakage.
Fig. 9 Upper Radiator Support 1 2 3 4
– – – –
UPPER FRONT UPPER UPPER
RADIATOR SUPPORT RETAINING BOLTS CLOSURE PANEL FAN SHROUD RETAINING BOLTS RADIATOR HOSE
(2) Remove the (2) upper fan shroud retaining bolts (Fig. 9). (3) Raise the vehicle on the hoist. (4) Remove the (2) lower fan shroud retaining bolts. (5) Remove the transmission oil drain plug and drain the transmission fluid. Reinstall the plug to contain residue fluid. NOTE: Mark the propeller shaft position in relation to the rear axle companion flange. The propeller shaft must be installed in the same position it was in before removal.
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REMOVAL AND INSTALLATION (Continued) (6) Remove the (4) universal joint clamp retaining bolts from the rear axle pinion. Remove the propeller shaft from the rear axle companion flange and tape the universal joint bearing caps in place. CAUTION: Wrap the universal joint bearing caps in place with tape to prevent the bearing caps from falling off. (7) Remove the (4) center propeller shaft bearing retaining nuts and remove the propeller shaft assembly from the vehicle. (8) Remove the (2) exhaust system inlet pipe retaining nuts. (9) Remove the exhaust system support bracket bolt from the clutch housing.
Fig. 11 Clutch Slave Cylinder 1 2 3 4
Fig. 10 Transmission Support Crossmember 1 2 3 4
– – – –
EXHAUST SYSTEM SUPPORT BRACKET RETAINING NUT CROSSMEMBER TRANSMISSION TRANSMISSION MOUNT RETAINING NUTS
(10) Remove the exhaust system support bracket nut from the transmission support crossmember (Fig. 10). (11) Remove the (2) clutch slave cylinder retaining nuts (Fig. 11). Remove the slave cylinder by pulling it straight off of the mounting studs. (12) Remove the (4) transmission mount retaining nuts from the transmission crossmember (Fig. 10). (13) Position a transmission jack and raise the transmission assembly enough to allow the crossmember to be slide straight back.
– – – –
SLAVE CYLINDER RETAINING NUTS HYDRAULIC CLUTCH SLAVE CYLINDER TRANSMISSION FLUID SUPPLY LINE
(14) Remove the fuel line support bracket retaining bolt from the transmission support crossmember. (15) Remove the transmission support crossmember retaining bolts. Slide the crossmember as far rearward as possible. (16) Lower the transmission assembly enough to access the shifter retaining bolts. (17) Remove the (4) shifter retaining bolts (Fig. 12). (18) Remove the (2) misfire sensor retaining bolts from the clutch housing. (19) Be sure all wiring is disconnected from the transmission assembly. (20) Secure the transmission to the transmission jack with safety chains. (21) Remove the clutch housing retaining bolts. Pull the transmission straight back until the input shaft clears the clutch assembly. Remove the transmission from the vehicle.
INSTALLATION (1) Make sure the transmission and engine mating surfaces are clean before installation. (2) Apply a light coat of Mopar high temperature bearing grease to the contact surfaces of the following components: • input shaft splines and pilot bearing hub.
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REMOVAL AND INSTALLATION (Continued)
Fig. 12 Shifter Assembly Retaining Bolts
Fig. 13 Transmission Mounting Bolts and Brackets
1 – SHIFTER ASSEMBLY RETAINING BOLTS 2 – TRANSMISSION
• release bearing slide surface retainer. • pilot bearing • release bearing bore • release fork • release ball stud • propeller shaft slip yoke
of
the
front
CAUTION: Do not allow any grease to come in contact with the clutch disc or its mating surfaces. If so, clean with suitable solvent before installation. (3) Position the transmission assembly and install the clutch housing retaining bolts (Fig. 13). Torque the bolts to 88 N·m (65 ft. lbs.). Be sure the housing is properly seated on the engine block before tightening bolts. NOTE: Do not install the 3 o–clock positioned clutch housing bolt at this time (Fig. 13). This bolt is also used to support the exhaust system. (4) Install the misfire sensor on the clutch housing. Torque the bolts to 27 N·m (20 ft. lbs.). (5) Install the shifter on the transmission (Fig. 14). Torque the bolts to 27 N·m (20 ft. lbs.). (6) Connect all wiring to the transmission assembly.
Fig. 14 Shifter Assembly Retaining Bolts 1 – SHIFTER ASSEMBLY RETAINING BOLTS 2 – TRANSMISSION
(7) Raise the transmission assembly enough to position the rear support crossmember.. (8) Install the transmission support crossmember. Torque the bolts to 65 N·m (48 ft. lbs.).
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REMOVAL AND INSTALLATION (Continued) (9) Install the fuel line support bracket on the transmission support crossmember.
Fig. 16 Clutch Slave Cylinder Fig. 15 Transmission Support Crossmember 1 2 3 4
– – – –
EXHAUST SYSTEM SUPPORT BRACKET RETAINING NUT CROSSMEMBER TRANSMISSION TRANSMISSION MOUNT RETAINING NUTS
(10) Install the (4) transmission mount retaining nuts (Fig. 15) on the transmission support crossmember. Torque the nuts to 47 N·m (35 ft. lbs.). (11) Install the (2) clutch slave cylinder retaining nuts (Fig. 16). Torque the nuts to 40 N·m (30 ft. lbs.). (12) Install the exhaust system support bracket nut on the transmission support crossmember. Torque the nut to 67 N·m (50 ft. lbs.). (13) Install the exhaust system support bracket bolt in the clutch housing. Torque the bolt to 88 N·m (65 ft. lbs.). (14) Install the (2) exhaust system inlet pipe retaining nuts. Torque the nuts to 36 N·m (27 ft. lbs.). (15) Install the propeller shaft assembly in its original position. Install the (4) center bearing retaining nuts and torque to 61 N·m (45 ft. lbs.). (16) Position the rear universal joint in the rear axle companion flange. Install the universal joint clamps and torque the retaining bolts to 27 N·m (20 ft. lbs.). (17) Install the (2) lower fan shroud retaining bolts. (18) Fill the transmission with fluid. Refer to Transmission Lubricant in this group for more information.
1 2 3 4
– – – –
SLAVE CYLINDER RETAINING NUTS HYDRAULIC CLUTCH SLAVE CYLINDER TRANSMISSION FLUID SUPPLY LINE
(19) Lower the vehicle on the hoist.
Fig. 17 Upper Radiator Support 1 2 3 4
– – – –
UPPER FRONT UPPER UPPER
RADIATOR SUPPORT RETAINING BOLTS CLOSURE PANEL FAN SHROUD RETAINING BOLTS RADIATOR HOSE
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REMOVAL AND INSTALLATION (Continued) (20) Install the (2) upper fan shroud retaining bolts (Fig. 17). (21) Connect the negative battery cable.
FRONT BEARING RETAINER SEAL REMOVAL (1) Remove release bearing and lever from the transmission. (2) Remove the bolts holding the front bearing retainer to the transmission case. (3) Remove the front bearing retainer from the transmission case. (4) Using a suitable pry tool, remove the front bearing retainer seal.
INSTALLATION
(4) Install the front bearing retainer onto the transmission case. (5) Install the bolts to hold the bearing retainer onto the transmission case. (6) Tighten the bolts to 17 N·m (12 ft. lbs.). (7) Install release bearing and lever onto the transmission.
EXTENSION HOUSING SEAL REMOVAL (1) Raise and support vehicle. (2) Remove propeller shaft. Refer to Group 3, Differential and Driveline, for proper procedures. (3) Using a suitable seal puller or screw with a slide hammer, remove the extension housing seal (Fig. 19).
(1) Using Tool Handle C-4171 and Seal Installer 8209, install new seal in to the front bearing retainer (Fig. 18).
Fig. 19 Remove Extension Housing Seal 1 – SLIDE HAMMER 2 – SEAL PULLER 3 – 2WD EXTENSION HOUSING
INSTALLATION
Fig. 18 Install Front Bearing Retainer Seal 1 – SPECIAL TOOL C-4171 2 – SPECIAL TOOL 8211 (AX5) OR 8209 (AX15)
(2) Remove any residual gasket material from the sealing surfaces of the bearing retainer and the transmission case. (3) Install new front bearing retainer gasket to the front bearing retainer.
(1) Clean seal bore of extension housing of any residual sealer material from original seal. (2) Using Tool Handle C-4171 and Seal Installer 8212, install new extension housing seal so that the seal is located 0 6 0.5 mm (0 6 0.02 in.) to the face of the extension housing (Fig. 20). (3) Install propeller shaft. Refer to Group 3, Differential and Driveline, for proper procedures. (4) Check and add fluid to transmission as necessary. Refer to the Recommended Lubricant section for proper fluid requirements. (5) Lower vehicle.
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 20 Install Extension Housing Seal 1 – SPECIAL TOOL C-4171 2 – SPECIAL TOOL 8212 3 – EXTENSION HOUSING
DISASSEMBLY AND ASSEMBLY ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER
Fig. 22 Remove Shift Tower Gasket 1 – SHIFT TOWER 2 – GASKET
(7) Remove reverse shift head detent ball plug (Fig. 24). (8) Remove detent ball spring and ball with pencil magnet (Fig. 25), (Fig. 26).
DISASSEMBLY (1) Drain transmission lubricant, if necessary. (2) Remove release bearing and lever. (3) Remove clutch housing bolts and remove housing (Fig. 23). (4) Remove bolts holding shift tower to transmission case. (5) Remove shift tower from transmission case (Fig. 21). (6) Remove shift tower gasket from shift tower or transmission case (Fig. 22).
Fig. 23 Clutch Housing Fig. 21 Remove Shift Tower 1 – SHIFT TOWER 2 – ADAPTER/EXTENSION HOUSING
1 – HOUSING -TO- TRANSMISSION BOLTS (38 N·m/28 ft. lbs.) 2 – CLUTCH HOUSING 3 – TRANSMISSION
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DISASSEMBLY AND ASSEMBLY (Continued) (9) Remove shift arm retainer bolt (Fig. 27). (10) Remove shift arm restrictor pins (Fig. 28). (11) Remove shift lever shaft plug (Fig. 29). (12) Remove shifter shaft with large magnet (Fig. 30). (13) Remove the shift arm from the adapter housing.
Fig. 24 Remove Detent Ball Plug 1 – DETENT PLUG
Fig. 27 Shift Arm Retainer Bolt Removal 1 – RETAINER BOLT 2 – SHIFT ARM
Fig. 25 Remove Detent Spring 1 – DETENT SPRING
Fig. 28 Shift Arm Rstrictor Pins 1 – RESTRICTOR PINS
Fig. 26 Remove Detent Ball 1 – DETENT BALL
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 29 Removing Shift Lever Shaft Plug 1 – SHIFT LEVER SHAFT PLUG
Fig. 30 Remove Shifter Shaft 1 – SHIFT ARM SHAFT 2 – LARGE MAGNET
(14) Remove adapter/extension housing bolts (Fig. 31). (15) Loosen adapter/extension housing by tapping it loose with plastic mallet (Fig. 32). (16) Remove adapter/extension housing (Fig. 33). (17) Remove the bolts holding the front bearing retainer to the transmission case.
Fig. 31 Adapter/Extension Housing Bolts
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DISASSEMBLY AND ASSEMBLY (Continued) (19) Remove input shaft bearing snap-ring (Fig. 35). (20) Remove cluster gear bearing snap-ring (Fig. 36).
Fig. 32 Loosen Adapter/Extension Housing 1 – INTERMEDIATE PLATE 2 – ADAPTER HOUSING 3 – RUBBER FACED MALLET
Fig. 34 Remove Front Bearing Retainer 1 – FRONT BEARING RETAINER
Fig. 33 Remove Adapter/Extension Housing 1 – ADAPTER HOUSING 2 – INTERMEDIATE PLATE
Fig. 35 Remove Input Shaft Bearing Snap-ring (18) Remove the bearing retainer from transmission case (Fig. 34).
1 – SNAP RING PLIERS 2 – INPUT SHAFT 3 – INPUT SHAFT BEARING SNAP RING
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 36 Remove Cluster Gear Snap-ring 1 – SNAP RING PLIERS 2 – CLUSTER GEAR FRONT BEARING SNAP RING
(21) Separate intermediate plate and transfer case by tapping them loose with plastic mallet (Fig. 37). (22) Separate the intermediate plate from the transmission case (Fig. 38).
Fig. 38 Remove Intermediate Plate from Transmission Case 1 – GEAR CASE 2 – INTERMEDIATE PLATE
(2) Apply a 1/8 to 3/16 inch wide bead of Threebondt Liquid Gasket TB1281, P/N 83504038, as shown, making sure to keep sealer bead to inside of bolt holes (Fig. 39). (3) Align geartrain and shift rails with mating holes in transmission case and install transmission case to the intermediate plate (Fig. 40). Verify that the transmission case is seated on the intermediate plate.
Fig. 37 Separate Intermediate Plate and Transmission Case 1 – INTERMEDIATE PLATE 2 – RUBBER MALLET 3 – GEAR CASE
Fig. 39 Apply Sealer to Transmission Gear Case
ASSEMBLY (1) Remove any residual sealer from transmission case, intermediate plate, adapter/extension housing, and front bearing retainer.
1 – SEALER BEAD (1/8” - 3/16” WIDE) 2 – GEAR CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 40 Install Transmission Gear Case to the Intermediate Plate 1 – GEAR CASE 2 – INTERMEDIATE PLATE
(4) Install new front bearing snap rings (Fig. 41).
Fig. 41 Install Front Bearing Snap-rings 1 – FRONT BEARING SNAP RINGS
(5) Apply 1/8 inch wide bead of Threebondt Liquid Gasket TB1281, P/N 83504038, to the front bearing retainer sealing surface. (6) Install the front bearing retainer (Fig. 42) and tighten bolts to 17 N·m (12 ft. lbs.).
Fig. 42 Install Front Bearing Retainer 1 – FRONT BEARING RETAINER
(7) Apply a 1/8 to 3/16 inch wide bead of Threebondt Liquid Gasket TB1281, P/N 83504038, to sealing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes. (8) Install adapter or extension housing on intermediate plate (Fig. 43). Tighten housing bolts to 37 N·m (27 ft. lbs.) torque. (9) Position shift arm in shifter tower opening of adapter/extension housing (Fig. 44). Be sure that the shifter arm is engaged into the shift rails.
Fig. 43 Install Adapter/Extension Housing 1 – ADAPTER HOUSING 2 – INTERMEDIATE PLATE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 44 Position Shift Arm in Transmission Case 1 – SHIFT ARM
Fig. 46 Install Shift Arm Retainer Bolt 1 – RETAINER BOLT 2 – SHIFT ARM
(10) Start shifter arm shaft in hole in back of adapter/extension housing. Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adapter/extension housing (Fig. 45). (11) Rotate the shifter arm shaft until the hole in the shift arm is aligned with the hole in the shaft. (12) Install the shift arm retainer bolt and tighten to 38 N·m (28 ft. lbs.) (Fig. 46). (13) Install and tighten shifter arm shaft plug to 18 N·m (13 ft. lbs.) torque (Fig. 47).
Fig. 47 Shifter Arm Shaft Plug Installation 1 – SHAFT PLUG
Fig. 45 Install Shifter Arm Shaft 1 – SHIFT ARM 2 – ADAPTER OR EXTENSION HOUSING
(14) Install shifter restrictor pins in shift tower and tighten to 27 N·m (20 ft. lbs.) (Fig. 48). (15) Install shift detent ball in detent opening (Fig. 49). (16) Install detent spring (Fig. 50). (17) Install detent plug and tighten to 19 N·m (14 ft. lbs.) (Fig. 51).
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 48 Install Shifter Restrictor Pins 1 – RESTRICTOR PINS
Fig. 51 Install Detent Ball Plug 1 – DETENT PLUG
(18) Install shift tower and new gasket on housing (Fig. 52). Tighten tower bolts to 18 N·m (13 ft. lbs.) torque. (19) Install new metal o-ring to the backup lamp switch. (20) Install backup lamp switch (Fig. 52). Tighten switch to 37 N·m (27 ft. lbs.) torque.
Fig. 49 Install Detent Ball 1 – DETENT BALL
Fig. 52 Installing Shift Tower And Backup Lamp Switch 1 – SHIFT TOWER 2 – BACKUP LAMP SWITCH
(21) Install new seal in adapter/extension housing. (22) Install clutch housing, release bearing, release fork and retainer clip.
Fig. 50 Install Detent Spring 1 – DETENT SPRING
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DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT MECHANISM AND GEARTRAIN DISASSEMBLY (1) Install suitable bolts and washers in intermediate plate (Fig. 53). Then clamp plate and gear assembly in vise. Use enough washers to prevent bolts from touching. Also be sure vise jaws are clamped on bolt heads.
Fig. 53 Positioning Intermediate Plate In Vise 1 – VISE JAWS 2 – BOLTS AND WASHERS
3 – INTERMEDIATE PLATE
(2) Measure thrust clearance between countershaft fifth gear and thrust ring with feeler gauge. Clearance should be 0.10 to 0.40 mm (0.003 to 0.019 in.). If clearance exceeds limits, gear and/or ring will have to be replaced. (3) Remove countershaft fifth gear retaining snapring (Fig. 54).
Fig. 54 Remove Fifth Gear Snap-ring 1 – FIFTH GEAR SNAP RING (SELECT FIT)
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DISASSEMBLY AND ASSEMBLY (Continued) (4) Remove bolt holding fifth gear shift fork to shift rail (Fig. 55).
(7) Remove the reverse shift head and rail assembly from the intermediate plate (Fig. 57). (8) Remove fifth gear blocker ring from countershaft assembly with Puller L-4407 (Fig. 58).
Fig. 55 Remove Fifth Gear Shift Fork Retainer Bolt 1 – SHIFT FORK SET SCREW 2 – FIFTH GEAR SHIFT RAIL 3 – FIFTH GEAR SHIFT FORK
Fig. 57 Remove Reverse Shift Head Assembly 1 – REVERSE SHIFT HEAD AND SHIFT RAIL
(5) Move fifth gear shift rail forward until the rail is clear of the shift fork. (6) Remove the fifth gear shift fork from the synchronizer sleeve (Fig. 56).
Fig. 56 Remove Fifth Gear Shift Fork 1 – FIFTH GEAR SHIFT FORK 2 – FIFTH GEAR SYNCHRO SLEEVE
Fig. 58 Remove Fifth Gear Blocker Ring 1 – FIFTH GEAR BLOCKER RING
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DISASSEMBLY AND ASSEMBLY (Continued) (9) Remove fifth gear synchro ring (Fig. 59).
Fig. 61 Remove Fifth Gear Thrust Ring Fig. 59 Remove Fifth Gear Synchro Ring 1 – FIFTH GEAR SYNCHRO RING
(10) Remove the countershaft fifth gear assembly from countershaft (Fig. 60).
1 – LOCK BALL NOTCH 2 – FIFTH GEAR THRUST RING
NOTE: There are many lock balls, check balls, interlock balls, and interlock pins used in various places in the transmission. Whenever a pin or ball is removed, it should be identified in such a way that it can be reinstalled in the same location from which it was removed.
Fig. 60 Remove Fifth Gear And Synchro Assembly 1 – FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY 2 – COUNTER FIFTH GEAR
(11) Remove fifth gear thrust ring from countershaft (Fig. 61). (12) Remove fifth gear thrust ring lock ball from countershaft (Fig. 62).
Fig. 62 Remove Fifth Gear Thrust Ring Lock Ball 1 2 3 4
– – – –
PENCIL MAGNET CLUSTER GEAR LOCK BALL RECESS THRUST RING LOCK BALL
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DISASSEMBLY AND ASSEMBLY (Continued) (13) Remove bolts holding output shaft rear bearing retainer to intermediate plate (Fig. 63).
Fig. 63 Remove Output Shaft Rear Bearing Retainer Bolts 1 – BEARING RETAINER 2 – BEARING RETAINER BOLTS 3 – SOCKET AND EXTENSION
(14) Remove rear bearing retainer (Fig. 64).
(15) Remove reverse idler gear shaft and gear (Fig. 65).
Fig. 65 Remove Reverse Idler Shaft And Gear 1 – REVERSE IDLER GEAR 2 – REVERSE IDLER SHAFT
(16) Remove bolts holding reverse shift arm bracket to intermediate plate (Fig. 66). (17) Remove threaded lock ball plugs from intermediate plate (Fig. 67). (18) Then remove lock ball and spring from plug holes with pencil magnet (Fig. 68).
Fig. 64 Remove Output Shaft Rear Bearing Retainer 1 – OUTPUT SHAFT REAR BEARING RETAINER
Fig. 66 Reverse Shift Arm Components 1 2 3 4
– – – –
SHIFT ARM BRACKET REVERSE SHIFT ARM REVERSE FORK E-CLIP
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 67 Lock Ball Plug Locations 1 – LOCK BALL PLUGS 2 – INTERMEDIATE PLATE
Fig. 68 Remove Lock Ball And Spring 1 2 3 4
– – – –
DETENT SPRINGS PENCIL MAGNET DETENT BALLS PENCIL MAGNET
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R1 DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 69 Shift Rail Identification 1 2 3 4
– – – –
REVERSE SHIFT FORK REVERSE SHIFT ARM FIFTH GEAR SHIFT RAIL REVERSE SHIFT RAIL (FRONT)
5 6 7 8
– – – –
3–4 1–2 1–2 3–4
SHIFT SHIFT SHIFT SHIFT
FORK RAIL FORK RAIL
(19) Remove the fifth gear shift rail (Fig. 69). (20) Retrieve the fifth gear shift rail lock ball from the intermediate plate using a magnet (Fig. 70). (21) Remove the 1–2 and 3–4 shift rail c-rings using two equally sized screwdrivers (Fig. 71).
Fig. 70 Remove Fifth Gear Shift Rail Lock Ball 1 – REVERSE SHIFT FORK 2 – MAGNET 3 – LOCK BALL
Fig. 71 Remove Shift Rail C-rings 1 – SHIFT RAIL C-RINGS
21 - 23
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DISASSEMBLY AND ASSEMBLY (Continued) (22) Remove bolts holding 1–2 and 3–4 shift forks to the shift rails (Fig. 72) and discard bolts.
Fig. 74 Remove 3–4 Shift Rail Interlock Plug Fig. 72 Remove Shift Fork To Shift Rail Bolts
1 – 3–4 SHIFT RAIL INTERLOCK PLUG 2 – MAGNET
1 – SHIFT FORK SET SCREWS
(23) Remove the 3–4 shift rail from the 1–2 and 3–4 shift forks and the intermediate plate (Fig. 73).
Fig. 73 Remove 3–4 Shift Rail 1 – 3–4 SHIFT RAIL
(24) Remove the 3–4 shift rail interlock plug from the intermediate plate with a small magnet (Fig. 74). (25) Remove the 3–4 shift fork (Fig. 75).
Fig. 75 Remove Shift Forks 1 – 3–4 SHIFT FORK 2 – 1–2 SHIFT FORK
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DISASSEMBLY AND ASSEMBLY (Continued) (26) Remove the 1–2 shift rail from the 1–2 shift fork and the intermediate plate (Fig. 76). (27) Remove the 1–2 shift rail interlock pin from the 1–2 shift rail (Fig. 77). (28) Remove the 1–2 shift rail interlock plug from the intermediate plate (Fig. 78). (29) Remove the 1–2 shift fork (Fig. 75).
Fig. 78 Remove 1–2 Shift Rail Interlock Plug 1 – 1–2 SHIFT RAIL INTERLOCK PLUG 2 – INTERMEDIATE PLATE 3 – MAGNET
Fig. 76 Remove 1–2 Shift Rail 1 – INTERMEDIATE PLATE 2 – 1–2 FORK 3 – 1–2 SHIFT RAIL
Fig. 77 Remove 1–2 Shift Rail Interlock Pin 1 – 1–2 SHIFT RAIL INTERLOCK PIN 2 – 1–2 SHIFT RAIL 3 – MAGNET
(30) Remove the c-ring holding the reverse shift rail into the intermediate plate using two equally sized screwdrivers (Fig. 79).
Fig. 79 Remove Reverse Shift Rail C-ring 1 – C-RING 2 – REVERSE SHIFT RAIL
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DISASSEMBLY AND ASSEMBLY (Continued) (31) Remove the reverse shift rail and fork from the intermediate plate (Fig. 80). (32) Remove the interlock pin from the reverse shift rail (Fig. 81).
Fig. 82 Remove Output Shaft Rear Bearing Snap-ring 1 – OUTPUT SHAFT REAR BEARING SNAP-RING 2 – COUNTERSHAFT REAR BEARING SNAP-RING
Fig. 80 Remove Reverse Shift Rail 1 – REVERSE SHIFT RAIL AND FORK 2 – REVERSE SHIFT RAIL BORE
removed by moving the mainshaft rearward and upward (Fig. 83). (36) Remove the countershaft by moving the countershaft rearward until the countershaft is clear of the intermediate plate. (37) Remove the countershaft rear bearing from the intermediate plate.
Fig. 81 Remove Reverse Shift Rail Interlock Pin 1 2 3 4
– – – –
REVERSE SHIFT RAIL MAGNET INTERLOCK PIN REVERSE SHIFT FORK
Fig. 83 Remove Mainshaft 1 – INPUT AND OUTPUT SHAFT GEAR ASSEMBLIES
(33) Remove snap-ring holding output shaft rear bearing into the intermediate plate (Fig. 82). (34) Remove countershaft rear bearing snap-ring. (35) With aid of an assistant, support the mainshaft and countershaft. Tap on the rear of the mainshaft and countershaft with a suitable rubber mallet. This will release the countershaft from the countershaft rear bearing and the mainshaft rear bearing from the intermediate plate. The mainshaft will release from the intermediate plate first and can be
ASSEMBLY (1) Lubricate countershaft journal and rear bearing with petroleum jelly or gear lubricant. (2) Position the mainshaft into the intermediate plate. (3) Tap the mainshaft assembly rear bearing into the intermediate plate with a suitable rubber mallet.
AX15 MANUAL TRANSMISSION
R1 DISASSEMBLY AND ASSEMBLY (Continued) (4) Install the countershaft thru the countershaft rear bearing journal of the intermediate plate. (5) Align and mesh the mainshaft and countershaft gears as much as possible. (6) Install the countershaft bearing over the countershaft bearing boss and into the intermediate plate. Be sure to leave the snap-ring groove in the bearing facing the rear of the unit. It may be necessary to tap on the bearing with a plastic mallet to fully seat the bearing into intermediate plate. (7) Verify that the mainshaft and countershaft gears are correctly meshed and rotate properly. (8) Install snap-ring to hold output shaft rear bearing into the intermediate plate (Fig. 68). (9) Install countershaft rear bearing snap-ring. NOTE: Coat all shift components with petroleum jelly during assembly. Petroleum jelly will hold components in position during installation.
Fig. 85 Install Reverse Shift Rail 1 – REVERSE SHIFT RAIL AND FORK 2 – REVERSE SHIFT RAIL BORE
(10) Install interlock pin in reverse shift rail (Fig. 84). (11) Install the reverse shift rail in the intermediate plate (Fig. 85).
Fig. 84 Install Reverse Shift Rail Interlock Pin 1 2 3 4
– – – –
REVERSE SHIFT RAIL MAGNET INTERLOCK PIN REVERSE SHIFT FORK
(12) Install c-ring to hold the reverse shift rail into the intermediate plate. (13) Install the 1–2 and 3–4 shift forks into the synchronizer sleeves (Fig. 86).
Fig. 86 Install Shift Forks 1 – 3–4 SHIFT FORK 2 – 1–2 SHIFT FORK
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DISASSEMBLY AND ASSEMBLY (Continued) (14) Install 1–2 shift rail interlock plug in the intermediate plate (Fig. 87). (15) Install interlock pin in 1–2 shift rail (Fig. 88).
(16) Install 1–2 shift rail through intermediate plate and 1–2 shift fork (Fig. 89). (17) Install 3–4 shift rail interlock plug into the intermediate plate (Fig. 90). (18) Install the 3–4 shift rail through the intermediate plate, 1–2 and 3–4 shift forks (Fig. 91).
Fig. 87 Install 1–2 Shift Rail Interlock Plug 1 – 1–2 SHIFT RAIL INTERLOCK PLUG 2 – INTERMEDIATE PLATE 3 – MAGNET
Fig. 89 Install 1–2 Shift Rail 1 – INTERMEDIATE PLATE 2 – 1–2 FORK 3 – 1–2 SHIFT RAIL
Fig. 88 Install 1–2 Shift Rail Interlock Pin 1 – 1–2 SHIFT RAIL INTERLOCK PIN 2 – 1–2 SHIFT RAIL 3 – MAGNET
Fig. 90 Install 3–4 Shift Rail Interlock Plug 1 – 3–4 SHIFT RAIL INTERLOCK PLUG 2 – MAGNET
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 91 Install 3–4 Shift Rail 1 – 3–4 SHIFT RAIL
(19) Install new bolts to hold the shift forks to the shift rails (Fig. 92). (20) Install c-rings to 1–2 and 3–4 shift rails (Fig. 93).
Fig. 93 Install Shift Rail C-rings 1 – C-RINGS 2 – 3–4 RAIL 3 – 1–2 RAIL
Fig. 94 Install Reverse Idler Gear And Shaft Fig. 92 Install Shift Fork To Shift Rail Bolts 1 – SHIFT FORK SET SCREWS
(21) Install the fifth gear shift rail lock ball in the intermediate plate (Fig. 96). (22) Install the fifth gear shift rail into the intermediate plate.
1 2 3 4
– – – –
REVERSE IDLER GEAR INTERMEDIATE PLATE REVERSE IDLER SHAFT SHAFT NOTCH
(23) Install reverse idler gear and idler gear shaft (Fig. 94). Verify that the notch in the idler shaft is to the rear of the transmission. (24) Position output shaft rear bearing retainer on intermediate plate and into reverse idler shaft notch.
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DISASSEMBLY AND ASSEMBLY (Continued) (25) Install new bolts to hold retainer to intermediate plate (Fig. 95).
Fig. 97 Install Fifth Gear Thrust Ring Lock Ball Fig. 95 Install Output Shaft Rear Bearing Retainer 1 – REAR BEARING RETAINER TAB 2 – REVERSE IDLER SHAFT NOTCH
(26) Install the fifth gear thrust ring lock ball into the countershaft (Fig. 97).
1 2 3 4
– – – –
PENCIL MAGNET CLUSTER GEAR LOCK BALL RECESS THRUST RING LOCK BALL
(27) Install fifth gear thrust ring onto countershaft and over lock ball (Fig. 98). (28) Install countershaft fifth gear bearing halves into countershaft fifth gear assembly (Fig. 99).
Fig. 96 Install Fifth Gear Shift Rail Lock Ball 1 – REVERSE SHIFT FORK 2 – MAGNET 3 – LOCK BALL
Fig. 98 Install Fifth Gear Thrust Ring 1 – LOCK BALL NOTCH 2 – FIFTH GEAR THRUST RING
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 99 Install Countershaft Fifth Gear Bearings 1 – TWO-PIECE BEARING 2 – COUNTER FIFTH GEAR AND SYNCHRO ASSEMBLY
(29) Install countershaft fifth gear assembly onto countershaft (Fig. 100). NOTE: The fifth gear synchronizer sleeve can be installed onto the countershaft backwards. Be sure to install the fifth gear synchronizer onto the countershaft with the step on the outer edge of the synchronizer sleeve towards fifth gear.
Fig. 101 Install Fifth Gear Synchronizer Ring 1 – FIFTH GEAR SYNCHRO RING
(33) Select the thickest snap-ring the will fit into the snap–ring groove of the countershaft. (34) Install snap-ring to hold the countershaft fifth gear assembly onto the countershaft (Fig. 102). (35) Install the reverse shift head and rail assembly (Fig. 103).
(30) Install fifth gear synchronizer ring (Fig. 101).
I.D. MARK
Fig. 100 Install Countershaft Fifth Gear Assembly 1 – FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY 2 – COUNTER FIFTH GEAR
(31) Position fifth gear blocker ring onto countershaft. Verify that blocker ring and countershaft splines are aligned. (32) Using a suitable driver and mallet, seat the blocker ring onto the countershaft.
A B C D E F G H
SNAP RING THICKNESS 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
-
2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25
MM (IN.) (0.1122 - 0.1142) (0.1142 - 0.1161) (0.1161 - 0.1181) (0.1181 - 0.1201) (0.1201 - 0.1220) (0.1220 - 0.1240) (0.1240 - 0.1260) (0.1260 - 0.1280)
Fig. 102 Install Fifth Gear Snap-ring 1 – FIFTH GEAR SELECTIVE SNAP RING
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 103 Install Reverse Shift Head And Rail Assembly 1 – REVERSE SHIFT HEAD AND SHIFT RAIL
(36) Move reverse shift rail forward as far as possible and install fifth gear shift fork onto synchronizer sleeve (Fig. 104). (37) Install new bolt to hold fifth gear shift fork to shift rail (Fig. 105).
Fig. 105 Install Fifth Gear Shift Fork Retainer Bolt 1 2 3 4
– – – –
REVERSE SHIFT-HEAD AND RAIL SHIFT FORK SET SCREW FIFTH GEAR SHIFT FORK FIFTH GEAR SHIFT RAIL
1 2 3 4
– – – –
DETENT SPRINGS PENCIL MAGNET DETENT BALLS PENCIL MAGNET
Fig. 104 Install Fifth Gear Shift Fork 1 – FIFTH GEAR SHIFT FORK 2 – FIFTH GEAR SYNCHRO SLEEVE
(38) Install detent balls and springs into openings in the intermediate plate (Fig. 106). (39) Install new lock ball plugs into the intermediate plate. Tighten plugs to 19 N·m (14 ft. lbs.). (40) Install bolts to hold reverse shift arm to the intermediate plate. Tighten bolts to 18 N·m (13 ft. lbs.).
Fig. 106 Install Detent Balls And Springs
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DISASSEMBLY AND ASSEMBLY (Continued)
COUNTERSHAFT
INPUT SHAFT
DISASSEMBLY
DISASSEMBLY
(1) Remove select fit snap-ring holding the countershaft front bearing onto the countershaft (Fig. 107). (2) Using Bearing Splitter P-334, a suitable spacer on center of countershaft, and a shop press, remove the countershaft front bearing from the countershaft.
(1) Verify that the 3–4 synchronizer is in the neutral position. (2) Separate input shaft from output shaft (Fig. 108).
I.D. MARK A B C D E
SNAP RING THICKNESS MM (IN.)
Fig. 108 Separate Input and Output Shafts 2.00 2.05 2.10 2.15 2.20
-
2.05 2.10 2.15 2.20 2.25
(0.0787 (0.0807 (0.0827 (0.0846 (0.0866
-
0.0807) 0.0827) 0.0846) 0.0866) 0.0886)
Fig. 107 Countershaft Front Bearing Snap-ring
1 – INPUT SHAFT ASSEMBLY 2 – OUTPUT SHAFT AND GEAR ASSEMBLY
(3) Remove the output shaft pilot bearing from the input shaft or output shaft (Fig. 109). (4) Remove the fourth gear synchronizer ring from the input shaft (Fig. 110).
1 – SELECT FIT RING 2 – COUNTERSHAFT 3 – FRONT BEARING
ASSEMBLY (1) Remove any nicks or burrs on countershaft hub with fine emery or crocus cloth. (2) Position countershaft front bearing on end of countershaft. Be sure the snap-ring groove in bearing is facing forward. (3) Using Special Tool 8109 and a shop press, press bearing onto countershaft. (4) Select the thickest snap-ring that will fit into the snap-ring groove of the countershaft (Fig. 107). (5) Install snap-ring to hold countershaft front bearing onto countershaft.
Fig. 109 Remove Output Shaft Pilot Bearing 1 – OUTPUT SHAFT PILOT BEARING 2 – INPUT SHAFT ASSEMBLY
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DISASSEMBLY AND ASSEMBLY (Continued)
I.D. MARK
Fig. 110 Input Shaft Components 1 2 3 4
– – – –
BEARING SYNCHRO RING INPUT SHAFT BEARING SNAP RING
(5) Remove the select fit snap-ring holding the input shaft bearing onto the input shaft. (6) Using Bearing Splitter P-334 and a shop press, remove the bearing from the input shaft.
ASSEMBLY (1) Position input shaft bearing onto input shaft. Be sure that the snap-ring groove in the bearing is facing forward. (2) Using Driver 6052, drive bearing onto input shaft. (3) Select the thickest snap-ring that will fit into the snap-ring groove of the input shaft (Fig. 111). (4) Lubricate output shaft pilot bearing bore of input shaft with petroleum jelly.
SNAP RING THICKNESS
A B C D E F G
2.10 2.15 2.20 2.25 2.30 2.35 2.40
-
2.15 2.20 2.25 2.30 2.35 2.40 2.45
MM (IN.) (0.0827 (0.0846 (0.0866 (0.0886 (0.0906 (0.0925 (0.0945
-
0.0846) 0.0866) 0.0886) 0.0906) 0.0925) 0.0945) 0.0965)
Fig. 111 Select Input Shaft Bearing Snap-ring 1 – SELECT-FIT SNAP RING
(5) Install output shaft pilot bearing in input shaft bore (Fig. 109). (6) Install the fourth gear synchronizer ring onto the input shaft. (7) Install input shaft to output shaft.
OUTPUT SHAFT Refer to (Fig. 112) for parts identification during disassembly and assembly of the output shaft.
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 112 Output Shaft And Gears 1 – SNAP RING (SELECTIVE) 2 – 3–4 HUB 3 – INSERT SPRING 4 – 3–4 SLEEVE 5 – SYNCHRO RING 6 – THIRD GEAR 7 – NEEDLE BEARING 8 – OUTPUT SHAFT (2WD) 9 – FIRST/REVERSE HUB 10 – FIRST GEAR 11 – NEEDLE BEARING 12 – PIN 13 – REAR BEARING 14 – SNAP RING (SELECTIVE) 15 – FIFTH GEAR
DISASSEMBLY (1) Remove input shaft and output shaft pilot bearing from output shaft (Fig. 113), if necessary. (2) Measure and note thrust clearance of output shaft gears (Fig. 114). First gear clearance should be 0.10 – 0.40 mm (0.004 – 0.0197 in.). Second and third gear clearance should be 0.10 – 0.30 mm (0.003 – 0.0118 in.).
16 17 18 19 20 21 22 23 24 25 26 27 28 29
– – – – – – – – – – – – – –
THRUST WASHER FIRST GEAR SPACER SYNCHRO RING SNAP RING (SELECTIVE) INSERT SPRING INSERT (3) INSERT SPRING SYNCHRO RING NEEDLE BEARING SECOND GEAR REVERSE GEAR AND 1–2 SLEEVE OUTPUT SHAFT (4WD) INSERT (3) INSERT SPRING
(3) Remove output shaft fifth gear snap ring with two screwdrivers (Fig. 115). (4) Using Bearing Splitter P-334 or suitable press plates positioned under first gear, press fifth gear, rear bearing, first gear, and first gear thrust washer off output shaft (Fig. 116).
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 113 Remove Output Shaft Pilot Bearing 1 – OUTPUT SHAFT PILOT BEARING 2 – INPUT SHAFT ASSEMBLY
Fig. 115 Remove Fifth Gear Snap-ring 1 – SNAP RING
Fig. 114 Check Output Shaft Gear Thrust Clearance 1 2 3 4 5 6 7
– – – – – – –
THRUST WASHER FIRST GEAR REVERSE GEAR AND HUB SECOND GEAR THIRD GEAR 3–4 SYNCHRO SLEEVE AND HUB OUTPUT SHAFT FLANGE
(5) Remove first gear thrust washer locating pin from output shaft. (6) Remove first gear needle roller bearing from output shaft. (7) Remove first gear spacer from output shaft. (8) Remove first gear synchronizer ring.
Fig. 116 Remove Fifth Gear, First Gear Bearing, And Thrust Washer 1 – PRESS RAM 2 – OUTPUT SHAFT 3 – FIRST-FIFTH GEAR-BEARING ASSEMBLY
(9) Remove select fit snap-ring holding the 1–2 synchronizer/reverse gear onto the output shaft.
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DISASSEMBLY AND ASSEMBLY (Continued) (10) Using Bearing Splitter P-334 or suitable press plates positioned under second gear, press 1–2 synchronizer/reverse gear and second gear from output shaft (Fig. 117).
Fig. 118 Remove 3–4 Synchronizer Snap Ring 1 – 3–4 SYNCHRONIZER SNAP RING
Fig. 117 Remove Second Gear And 1–2 Synchronizer/Reverse Gear 1 – PRESS RAM 2 – SECOND GEAR 3 – 1–2 SYNCHRONIZER HUB
(11) Remove second gear needle roller bearing from the output shaft or second gear. (12) Remove select fit snap-ring holding the 3–4 synchronizer onto the output shaft (Fig. 118). (13) Using Bearing Splitter P-334 or suitable press plates positioned under third gear, press the 3–4 synchronizer and third gear from output shaft (Fig. 119). (14) Remove third gear needle roller bearing from output shaft or gear.
ASSEMBLY (1) Lubricate transmission components with specified gear lubricant during assembly. (2) If necessary, assemble 1–2 and 3–4 synchronizer hubs, sleeves, springs and key inserts (Fig. 120).
Fig. 119 Remove 3–4 Synchronizer And Third Gear 1 – 3–4 SYNCHRONIZER 2 – THIRD GEAR
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DISASSEMBLY AND ASSEMBLY (Continued) (9) Install snap-ring to hold 3–4 synchronizer onto output shaft. (10) Verify third gear thrust clearance with feeler gauge (Fig. 122). Clearance should be 0.10 – 0.30 mm (0.003 – 0.0118 in.). If clearance is out of specification, refer to Cleaning and Inspection section within this group.
Fig. 120 Synchronizer Identification 1 – 3–4 SLEEVE AND HUB 2 – REVERSE GEAR AND 1–2 SLEEVE AND HUB
(3) Install third gear needle bearing onto the output shaft. (4) Install third gear over bearing and onto output shaft flange. (5) Install third gear synchronizer ring to third gear. (6) Position the 3–4 synchronizer onto the output shaft. (7) Using Adapter 6761 and a shop press, press the 3–4 synchronizer onto the output shaft. (8) Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft (Fig. 121).
I.D. MARK A B C D E F G
SNAP RING THICKNESS 1.80 1.85 1.90 1.95 2.00 2.05 2.10
-
1.85 1.90 1.95 2.00 2.05 2.10 2.15
MM (IN.) (0.0709 (0.0728 (0.0748 (0.0768 (0.0787 (0.0807 (0.0827
-
0.0728) 0.0748) 0.0768) 0.0787) 0.0807) 0.0827) 0.0846)
Fig. 121 Select 3–4 Synchronizer Snap-ring
Fig. 122 Check Third Gear Clearance 1 – FEELER GAUGE 2 – THIRD GEAR
(11) Install second gear needle bearing onto output shaft. (12) Install second gear over bearing and onto output shaft flange. (13) Install second gear synchronizer ring onto second gear. (14) Position 1–2 synchronizer/reverse gear assembly onto splines of output shaft. (15) Using Driver MD-998805, Adapter 6761, and a shop press, press the 1–2 synchronizer/reverse gear onto the output shaft. (16) Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft (Fig. 123). (17) Install snap-ring to hold 1–2 synchronizer/reverse gear onto output shaft. (18) Install first gear synchronizer ring into 1–2 synchronizer/reverse gear. (19) Install the first gear spacer onto the input shaft and against the 1–2 synchronizer/reverse gear snap-ring. (20) Install first gear needle bearing onto output shaft (Fig. 124). (21) Install first gear onto output shaft and over bearing. (22) Install the first gear thrust washer locating pin into the output shaft.
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21 - 39
DISASSEMBLY AND ASSEMBLY (Continued)
I.D. MARK B C D E F G
SNAP RING THICKNESS 2.35 2.40 2.45 2.50 2.55 2.60
-
2.40 2.45 2.50 2.55 2.60 2.65
MM (IN.) (0.0925 (0.0945 (0.0965 (0.0984 (0.1004 (0.1024
-
0.0945) 0.0965) 0.0984) 0.1004) 0.1024) 0.1043)
Fig. 123 Second Gear And Synchronizer Assembly 1 2 3 4 5 6 7
– – – – – – –
SECOND GEAR REVERSE GEAR AND 1–2 SLEEVE FIRST/REVERSE HUB SELECT FIT SNAP RING INSERTS AND SPRINGS SYNCHRO RING NEEDLE BEARING
(23) Install the first gear thrust washer onto the output shaft. Rotate the thrust washer until the washer locating pin aligns with the notch in the washer. (24) Position output shaft rear bearing onto output shaft. Ensure that the snap ring groove in bearing outer race is toward rear of output shaft. (25) Using Driver L-4507 and suitable mallet, drive bearing onto output shaft. (26) Install snap-ring onto output shaft rear bearing outer race. (27) Check first and second gear thrust clearance (Fig. 125). First gear clearance should be 0.10 – 0.40 mm (0.003 – 0.0197 in.). Second gear clearance should be 0.10 – 0.30 mm (0.003 – 0.0118 in.). If clearance is out of specification, refer to Cleaning and Inspection section within this group. (28) Position fifth gear onto output shaft with the gear’s long shoulder toward the rear of shaft. Ensure that the gear and output shaft splines are aligned. (29) Using Adapter 6761, Driver L-4507, and a shop press, press fifth gear onto output shaft.
Fig. 124 First And Fifth Gear Components 1 2 3 4 5 6 7 8
– – – – – – – –
SYNCHRO RING SPACER PIN BEARING FIFTH GEAR THRUST WASHER NEEDLE BEARING FIRST GEAR
Fig. 125 Check First–Second Gear Thrust Clearance 1 2 3 4 5 6 7
– – – – – – –
THRUST WASHER FIRST GEAR REVERSE GEAR AND HUB SECOND GEAR THIRD GEAR 3–4 SYNCHRO SLEEVE AND HUB OUTPUT SHAFT FLANGE
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DISASSEMBLY AND ASSEMBLY (Continued) (30) Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft (Fig. 126).
GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE Clean the case, housing, and intermediate plate with solvent and dry with compressed air. Replace the case if cracked, porous, or if any of the bearing and gear bores are damaged. Inspect the threads in the case, housing, and plate. Minor thread damage can be repaired with steel thread inserts, if necessary. Do not attempt to repair any threads which show evidence of cracks around the threaded hole.
OUTPUT SHAFT Check thickness of the output shaft flange with a micrometer or vernier calipers (Fig. 127). Minimum allowable flange thickness is 4.70 mm (0.185 in.). I.D. MARK A B C D E F G H J K L M
SNAP RING THICKNESS 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30
-
2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35
MM (IN.) (0.1083 - 0.1102) (0.1102 - 0.1122) (0.1122 - 0.1142) (0.1142 - 0.1161) (0.1161 - 0.1181) (0.1181 - 0.1201) (0.1201 - 0.1220) (0.1220 - 0.1240) (0.1240 - 0.1260) (0.1260 - 0.1280) (0.1280 - 0.1299) (0.1299 - 0.1319)
Fig. 127 Check Output Shaft Tolerances 1 – CLUSTER GEAR JOURNAL
Fig. 126 Select/Install Fifth Gear Snap Ring 1 – TAP SNAP RING INTO PLACE
(31) Install snap-ring to hold fifth gear onto output shaft. (32) Install output shaft pilot bearing into the input shaft. (33) Install the input shaft to the output shafts.
CLEANING AND INSPECTION AX15 MANUAL TRANSMISSION COMPONENTS GENERAL INFORMATION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air. Dry the bearings with clean, dry shop towels only. Never use compressed air on the bearings. This could cause severe damage to the bearing roller and race surfaces. If output shaft flange thickness is within specification but any gear thrust clearance is out of specification, replace the necessary gear and gear needle bearing as an assembly.
Check diameter of the first, second, and third gear bearing surfaces on the output shaft. Minimum diameters are as follows: • First gear bearing surface is 38.86 mm (1.529 in.). • Second gear bearing surface is 46.86 mm (1.844 in.). • Third gear bearing surface is 37.86 mm (1.490 in.). Measure output shaft runout with a dial indicator and V-blocks (Fig. 127). Runout should not exceed 0.06 mm (0.0024 in.). Replace output shaft if measurement of any surface is out of specification. Do not attempt to repair out of specification components.
COUNTERSHAFT Inspect the countershaft gear teeth. Replace the countershaft if any teeth are worn or damaged. Inspect the bearing surfaces and replace shaft if any surface shows damage or wear. Check condition of the countershaft front bearing. Replace the bearing if worn, noisy, or damaged.
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21 - 41
CLEANING AND INSPECTION (Continued)
GEAR AND SYNCHRONIZER Install the needle bearings in the first, second, third and counter fifth gears. Install the gears on the output shaft. Then check oil clearance between the gears and shaft with a dial indicator (Fig. 128). Oil clearance for all three gears is 0.16 mm (0.0063 in.) maximum.
Fig. 129 Check Synchronizer Ring Wear 1 – FEELER GAUGE 2 – SYNCHRONIZER RING
Fig. 128 Check Gear–To–Shaft Oil Clearance 1 – GEAR BEING CHECKED 2 – OUTPUT SHAFT
Check synchronizer ring wear (Fig. 129). Insert each ring in matching gear. Measure clearance between each ring and gear with feeler gauge. Clearance should be 0.06 – 1.6 mm (0.024 – 0.063 in.). Check shift fork–to–synchronizer hub clearance with a feeler gauge (Fig. 130). Replace the fork if clearance exceeds 1.0 mm (0.039 in.). Check the condition of the reverse idler gear bushing (Fig. 131). Replace the gear if the bushing is damaged or worn.
Fig. 130 Check Fork–To–Hub Clearance 1 – SHIFT FORK 2 – FEELER GAUGE 3 – SYNCHRONIZER SLEEVE
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SPECIFICATIONS (Continued) DESCRIPTION TORQUE Bolts, Reverse Shift Arm Bracket . . . . . . . . 18 N·m (13 ft. lbs.) Screw, Shift Arm Set . . . . . . . . . 38 N·m (28 ft. lbs.) Screws, Shift Fork Set . . . . . . . 20 N·m (15 ft. lbs.) Nut, Shift Knob . . . . . . . 20–34 N·m (15–25 ft. lbs.) Screws, Shifter Floor Cover . . . . . . . . . . . . 2–3 N·m (17–30 in. lbs.) Bolt, Shift Arm . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
SPECIAL TOOLS AX15 Fig. 131 Reverse Idler Gear Bushing 1 – CHECK BUSHING FOR WEAR OR DAMAGE 2 – REVERSE IDLER GEAR
SPECIFICATIONS TORQUE DESCRIPTION TORQUE Back up Lamp Switch . . . . . . . . 37 N·m (27 ft. lbs.) Clutch Housing to (Diesel) Engine Block . . 88 N·m (65 ft. lbs.) Misfire Sensor to Clutch Housing . . . . . . . . 27 N·m (20 ft. lbs.) Shift Tower to Transmission Case . . . . . . . . 27 N·m (20 ft. lbs.) Transmission Support Crossmember . . . . . . 65 N·m (48 ft. lbs.) Transmission Mount to Crossmember . . . . . 47 N·m (35 ft. lbs.) Slave Cylinder to Clutch Housing . . . . . . . . 41 N·m (30 ft. lbs.) Exhaust System Support Bracket to Crossmember . . . . . . . . . . . . 67 N·m (50 ft. lbs.) Exhaust System Inlet Pipe Nuts . . . . . . . . . 36 N·m (27 ft. lbs.) Propeller Shaft Retainer Strap Nuts . . . . . . 27 N·m (20 ft. lbs.) Propeller Shaft Center Bearing . 61 N·m (45 ft. lbs.) Bearing Shim Cap (countershaft) . . . . . . . . 41 N·m (30 ft. lbs.) Drain/Fill Plug . . . . . . . . . . . . . 34 N·m (25 ft. lbs.) Shift Shaft Lock Bolt . . . . . . . . . 27 N·m (20 ft. lbs.) Plugs, Shift Arm, Lock ball . . . . 19 N·m (14 ft. lbs.) Bolts, Extension Housing . . . . . 37 N·m (27 ft. lbs.) Plugs, Drain and Fill . . . . . . . 44 N·m (32.5 ft. lbs.) Bolts, Front Bearing Retainer . . 17 N·m (12 ft. lbs.) Plugs, Interlock and Detent . . . 19 N·m (14 ft. lbs.) Pins, Shift Restrictor . . . . . . . 27.4 N·m (20 ft. lbs.)
C-3339 Dial Indicator Set
C-4171 Handle, Universal Tool
8209 Installer, Seal
AX15 MANUAL TRANSMISSION
R1 SPECIAL TOOLS (Continued)
8212 Installer, Seal
8109 Cup, Installer
8208 Installer, Seal
6052 Tube, Driver
L-4407A Puller, Gear 6761 Adapter, Installer
P-334 Splitter, Bearing
MD-998805 Tube, Driver
L-4507 Tube, Driver
21 - 43
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NV1500 TRANSMISSION
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NV1500 TRANSMISSION TABLE OF CONTENTS page
page
DESCRIPTION AND OPERATION NV1500 MANUAL TRANSMISSION. . . . . . . . . . . . 44 NV1500 IDENTIFICATION. . . . . . . . . . . . . . . . . . . 44 DISASSEMBLY AND ASSEMBLY TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DESCRIPTION AND OPERATION
The NV1500 manual transmission used in the R1 Dakota is similar to the NV1500 used in the AN Dakota. However similar, the R1 NV1500 does utilize different internal components and can be identified by part # 53015805AA.
NV1500 MANUAL TRANSMISSION The NV1500 is a medium-duty, 5-speed, constant mesh, fully synchronized manual transmission. The transmission gear case consists of two aluminum gear housings and a detachable clutch housing. The mainshaft is supported by two sealed ball bearings, and the countershaft is supported by two tapered roller bearings. The drive gears all rotate on caged type needle bearings. A roller bearing is used between the input and output shaft. The NV1500 has a single shaft shift mechanism with three shift forks all mounted on the shaft. The shaft is supported in the front and rear housings by bushings. Internal shift components consist of the forks, shaft, shift lever socket, and detent components The NV1500 manual transmission used in the R1 Dakota is similar to the NV1500 used in the AN Dakota. However similar, the R1 NV1500 can be identified by the following differences: • Heavy-duty synchro assemblies for first and second gear ranges. • Taller shift tower to accommodate different R1 Dakota drive line angle. Refer to transmission identification to verify the model of NV1500 being serviced. When disassembly and assembly of the R1 NV1500 is required follow the service procedure called out in this group of the service manual. For Diagnosis and Testing, Cleaning and Inspection, Removal and Installation procedures or required Special Service Tools, refer to the AN service manual.
DISASSEMBLY AND ASSEMBLY TRANSMISSION DISASSEMBLY FRONT HOUSING (1) If necessary, temporarily reinstall shift lever assembly. Shift transmission into Neutral. (2) If lubricant was not drained out of transmission during removal, remove drain plug and drain lubricant into container at this time. (3) Inspect drain plug magnet for debris. (4) Remove backup light switch. Switch is located on passenger side of rear housing (Fig. 1).
NV1500 IDENTIFICATION The NV1500 bar code tags are located on each side of the transmission, below the shift tower. The tag located on the left side has the build sequence and date information. The tag located on the right side has the part number.
Fig. 1 Backup Light Switch Location 1 – BACKUP LAMP SWITCH
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DISASSEMBLY AND ASSEMBLY (Continued) (5) If necessary, remove shift tower bolts and remove tower and lever assembly (Fig. 2).
(7) Use Remover 8117 and suitable slide hammer to remove shift shaft detent plug. (8) Remove shift shaft detent plunger and spring (Fig. 4). Use pencil magnet to remove spring then plunger, if necessary.
Fig. 2 Shift Tower Removal 1 – SHIFT TOWER AND LEVER ASSEMBLY 2 – SHIFT SOCKET 3 – SEAL
(6) Remove shift shaft lock bolt (Fig. 3). Bolt is located at top of front housing just forward of shift tower. Bolt is a shoulder bolt that secures the shift shaft bushing and lever.
Fig. 4 Detent Plunger And Spring Removal 1 2 3 4
– – – –
FRONT HOUSING PLUG SPRING PLUNGER
(9) Remove bolts attaching input shaft bearing retainer to front housing (Fig. 5).
Fig. 3 Shift Shaft Lock Bolt Removal 1 – SHIFT SHAFT LOCK BOLT 2 – SHAFT SOCKET
Fig. 5 Input Shaft Bearing Retainer Bolt Removal 1 – BOLTS (5) 2 – BEARING RETAINER
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DISASSEMBLY AND ASSEMBLY (Continued) (10) Remove input shaft bearing retainer. Use pry tool to carefully lift retainer and (11) Remove bearing retainer from input shaft (Fig. 6).
Fig. 6 Input Shaft Bearing Retainer Removal 1 – BEARING RETAINER 2 – OIL FEED
(12) Remove snap ring that secures input shaft in front bearing (Fig. 7).
Fig. 8 Housing And Bearing Retainer Bolt Locations 1 2 3 4
– – – –
RETAINER BOLTS HOUSING BOLTS RETAINER BOLT HOUSING BOLT LOCATIONS
1 2 3 4
– – – –
FRONT HOUSING REAR HOUSING DOWELS (2) PLASTIC MALLET
Fig. 7 Input Shaft Snap Ring Removal (Typical) 1 – INPUT SHAFT SNAP RING 2 – OIL FEED
(13) Remove bolts that attach front housing to rear housing (Fig. 8). Three bolts at extreme rear of housing are actually for the output shaft bearing retainer. It is not necessary to remove all three bolts at this time. Leave at least one bolt in place until geartrain is ready to be removed from case. (14) Separate front housing from rear housing (Fig. 9). Use plastic mallet to tap front housing off alignment dowels.
Fig. 9 Front Housing Removal
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DISASSEMBLY AND ASSEMBLY (Continued) (15) Remove and inspect input shaft bearing. Inspect countershaft front bearing race (Fig. 10).
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT (1) Using a hammer and suitable punch, drive out roll pin that secures shift bushing and lever to shift shaft (Fig. 12).
Fig. 10 Input Shaft Bearing and Countershaft Front Bearing Race Location 1 – COUNTERSHAFT FRONT BEARING RACE 2 – INPUT SHAFT BEARING 3 – FRONT HOUSING
(16) Note position of input shaft, shift shaft and forks, and geartrain components in housing (Fig. 11).
Fig. 12 Removing Shift Shaft Lever And Bushing Roll Pin 1 – PIN PUNCH 2 – BUSHING AND LEVER 3 – SHIFT SHAFT
(2) Position shift socket off to the side so that roll pin removal does not interfere with gears. (3) Using a hammer and suitable punch, drive out shift socket roll pin to release shift socket from shaft. Roll pin will fall to bottom of rear housing and is easily retrieved. NOTE: Be sure to use the proper size punch to prevent damage to the shift shaft. (4) Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork, and 1-2 fork (Fig. 13).
Fig. 11 Geartrain And Shift Component Identification 1 2 3 4 5 6 7 8 9
– – – – – – – – –
SHIFT SHAFT BUSHING REAR HOUSING REVERSE IDLER AND SUPPORT OUTPUT SHAFT AND GEARS COUNTERSHAFT 1–2 FORK INPUT SHAFT 3–4 FORK
Fig. 13 Shift Shaft Removal 1 – SHIFT SHAFT 2 – 3–4 FORK 3 – SHAFT DETENT NOTCHES
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DISASSEMBLY AND ASSEMBLY (Continued) (5) Remove shift socket from rear housing (Fig. 14).
Fig. 14 Shift Socket And Roll Pin 1 – SHAFT BORE 2 – ROLL PIN 3 – SHIFT SOCKET
(6) Remove lever and bushing (Fig. 15).
Fig. 16 Removing 3-4 Shift Fork 1 – 3–4 FORK 2 – 1–2 AND 5TH-REVERSE FORK ARMS 3 – 3–4 SYNCHRO SLEEVE
Fig. 15 Removing Shift Shaft Lever And Bushing 1 – SHAFT LEVER AND BUSHING 2 – 3–4 FORK
Fig. 17 Reverse Idler Shaft/Support Bolts (7) Remove 3-4 fork. 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. 16). (8) Remove the reverse idler shaft support bolt (front bolt) (Fig. 17). (9) Loosen rear reverse idler shaft bolt (rear bolt) (Fig. 17).
1 – SUPPORT BOLT 2 – SHAFT BOLT
(10) Remove reverse idler shaft support segment by sliding it straight out of housing. (11) Remove reverse idler shaft bolt (rear bolt). (12) Remove reverse idler shaft, idler gear, bearing, and thrust washer (Fig. 18).
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 18 Reverse Idler Assembly 1 2 3 4 5
– – – – –
SUPPORT BEARING WASHER GEAR SHAFT
GEARTRAIN (1) Remove three bolts that attach output shaft bearing retainer to rear case (Fig. 19). Bolts are rear of shift tower opening.
Fig. 20 Removing Geartrain from Rear Housing 1 – REAR HOUSING 2 – SHIFT FORKS AND GEARTRAIN
(3) Examine condition of output shaft rear bearing bore and idler shaft notch in rear housing. Replace housing if any of these components are damaged. Inspect countershaft rear bearing race and replace if necessary. PRELIMINARY GEARTRAIN (1) Remove 1-2 and fifth-reverse forks from synchro sleeves. (2) Separate countershaft from mainshaft. (3) Separate input shaft from output shaft. (4) Inspect input/output shaft pilot bearing, input shaft pocket bore, and 4th gear synchro ring. Replace if necessary.
Fig. 19 Removing/Installing Output Shaft Bearing Retainer Bolts 1 – OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT IS AT OPPOSITE SIDE OF CASE)
(2) Grab hold of mainshaft and countershaft and remove geartrain from rear housing (Fig. 20).
COUNTERSHAFT (1) Remove countershaft front and rear bearing with Puller 8356. (2) Remove rear bearing race (in rear housing) with Bearing Race Remover L-4454. Install new race with Race Driver C-4656 and Driver Handle C-4171. (3) Remove bearing shim cap from front housing (below input shaft bearing retainer). Remove shim. Drive race through and out of housing with Race Driver C-4656 and Driver Handle C-4171. Install new race and drive into housing from outside. Do not drive all the way into position. Tightening the shim cap will install the race to the proper position. Install shim and shim cap and torque the shim cap bolts to 28.5 N·m (21 ft. lbs.).
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DISASSEMBLY AND ASSEMBLY (Continued) OUTPUT SHAFT NOTE: The synchronizer hubs and sleeves are different and must not be intermixed. It is recommended that each synchronizer unit be removed as an assembly to avoid intermixing parts. It is also recommended that each synchro hub and sleeve be marked with a scriber or paint for correct assembly reference. (1) Remove snap ring that secures 3-4 synchro hub on output shaft. (2) Remove 3-4 synchro assembly, third gear synchro ring, and third gear with shop press and Remover Tool 1130. Position Tool 1130 between second and third gears. (3) Remove third gear needle bearing (Fig. 21).
Fig. 22 Two-Piece Thrust Washer Removal 1 – WASHER (2 HALVES) 2 – PIN RELIEF 3 – PIN
Fig. 21 Third Gear Needle Bearing Removal 1 – THIRD GEAR NEEDLE BEARING
(4) Remove retaining ring that secures two-piece thrust washer on shaft. (5) Remove two-piece thrust washer (Fig. 22). Note position of washer locating lugs in shaft notches for installation reference. (6) Remove second gear and needle bearing (Fig. 23). (7) Remove 2nd–3rd gear thrust washer locating pin and store in a place where it can be found easily upon re-assembly. (8) Remove second gear synchro ring and synchro cone. (9) Remove 1-2 synchro hub snap ring.
Fig. 23 Second Gear And Needle Bearing Removal 1 – SECOND GEAR 2 – SECOND GEAR NEEDLE BEARING
(10) Remove 1-2 synchro hub and sleeve and first gear from output shaft with shop press and Remover Tool 1130 (Fig. 24). Position Tool 1130 between first and reverse gears. (11) Remove first gear needle bearing (Fig. 25). (12) Remove output shaft bearing snap ring (Fig. 26).
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 24 Hub And Sleeve Removal—1-2 Synchro 1 – 1–2 SYNCHRO HUB AND SLEEVE 2 – SPECIAL TOOL 1130
Fig. 26 Output Shaft Bearing Snap Ring Removal 1 – OUTPUT SHAFT BEARING 2 – BEARING SNAP RING 3 – SNAP RING PLIERS
Fig. 25 First Gear Needle Bearing Removal
Fig. 27 Fifth Gear Removal 1 – FIFTH GEAR AND SYNCHRO RING
1 – FIRST GEAR NEEDLE BEARING
(13) Remove output shaft bearing from shaft with shop press and remover tool 1130. Position Tool 1130 between bearing and 5th gear. (14) Remove fifth gear (Fig. 27). (15) Remove fifth gear needle bearing. Spread bearing apart just enough to clear shoulder on output shaft (Fig. 28). (16) Remove fifth-reverse synchro hub snap ring (Fig. 29). (17) Remove fifth-reverse synchro hub and sleeve with shop press (Fig. 30). (18) Remove reverse gear and needle bearing (Fig. 31).
Fig. 28 Fifth Gear Needle Bearing Removal 1 – FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO CLEAR SHOULDER ON SHAFT)
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 31 Reverse Gear And Needle Bearing Removal 1 – REVERSE GEAR AND NEEDLE BEARING
ASSEMBLY Fig. 29 Fifth-Reverse Synchro Hub Snap Ring Removal 1 – FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 2 – SYNCHRO HUB SNAP RING 3 – SNAP RING PLIERS
Fig. 30 Fifth-Reverse Synchro Hub And Sleeve Removal 1 2 3 4
– – – –
PRESS FIFTH-REVERSE SYNCHRO HUB AND SLEEVE REVERSE GEAR OUTPUT SHAFT
COUNTERSHAFT Examine condition of countershaft gears and bearings. Worn or broken gears require shaft replacement. Inspect bearings for excessive wear, damaged cage, or missing rollers. If replacing countershaft bearings, the bearing race (located in front and rear housing) must be replaced also. SYNCHRONIZER The easiest method of assembling each synchro is to install the springs, struts and detent balls one at a time as follows: (1) Slide the sleeve part way onto the hub. Leave enough room to install the spring in the hub and the strut in the hub groove. (2) Install the first spring in the hub. Then install a strut over the spring. Be sure the spring is seated in the spring bore in the strut. (3) Slide the sleeve onto the hub just far enough to hold the first strut and spring in place. (4) Place the detent ball in the top of the strut. Then carefully work the sleeve over the ball to hold it in place. A small flat blade screwdriver can be used to press the ball into place while moving the sleeve over it. (5) Repeat the procedure for the remaining springs, struts and balls. Tape, or a rubber band can be used to temporarily secure each strut and ball as they are installed. (6) Verify synchro assembly. Be sure the three springs, struts and detent balls are all in place (Fig. 32).
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DISASSEMBLY AND ASSEMBLY (Continued) (3) Inspect and replace any synchro ring that exhibits wear or damage. Completely immerse each synchro ring in lubricant before installation. (4) Lubricate and install reverse gear needle bearing on shaft (Fig. 33). Slide bearing up against shoulder on output shaft.
Fig. 33 Reverse Gear Bearing Installation Fig. 32 Assembled View Of Synchro Components 1 2 3 4 5 6
– – – – – –
SLEEVE HUB SHOULDER SPRING (3) STRUT (3) DETENT BALL (3) HUB
1 – REVERSE GEAR BEARING 2 – SHOULDER
(5) Install reverse gear over needle bearing (Fig. 34).
OUTPUT SHAFT NOTE: The synchronizer sleeves must be assembled with the grooves toward the first, third, and fifth gear. Additional sleeve identification is as follows: • First and second: one groove on the outer diameter toward the first gear. The 1–2 synchro sleeve may not have the identification groove readily visible. If the groove is not present, the smaller land on the side of synchro sleeve can be used for orientation. The small land goes toward first gear. • Third and fourth: two grooves on the outer diameter toward the third gear. • Fifth and reverse: two grooves on the outer diameter toward the fifth gear. (1) Lubricate shaft, gears and bearings with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place. (2) Check bearing surfaces of output shaft for nicks or scratches. Smooth surfaces with 320/400 grit emery cloth if necessary. Apply oil to emery cloth and shaft surface before polishing.
Fig. 34 Reverse Gear Installation 1 – REVERSE GEAR
(6) Install solid brass synchro ring on reverse gear (Fig. 35). NOTE: This synchro ring is different than all the rest. The angle on the friction face is 9° versus the 6.5° of all the other synchro rings. Check to be sure that the right one is used. (7) Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done. CAUTION: The fifth-reverse synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has double grooves and offset teeth. This side is to be installed away from reverse gear (towards 5th).
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DISASSEMBLY AND ASSEMBLY (Continued) (9) Install new fifth-reverse hub snap ring (Fig. 37) as follows: (a) Install thickest snap ring that will fit in shaft groove. (b) Verify that snap ring is completely seated in groove before proceeding.
Fig. 35 Reverse Gear Synchro Ring Installation 1 – REVERSE GEAR 2 – SYNCHRO RING (SOLID BRASS)
(8) Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover 6310-1 (Fig. 36). NOTE: The synchro hub is designed such that the press should be necessary to install the synchro assembly onto the output shaft. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.
Fig. 37 Installing Fifth-Reverse Synchro Hub Snap Ring 1 2 3 4
– – – –
FIFTH-REVERSE SYNCHRO ASSEMBLY SNAP RING PRESS BED PRESS BLOCKS
(10) Install fifth gear synchro ring in synchro hub and sleeve (Fig. 38).
Fig. 36 Fifth-Reverse Synchro Assembly Installation 1 2 3 4 5 6 7
– – – – – – –
SPACER PRESS RAM REVERSE GEAR FIFTH-REVERSE SYNCHRO ASSEMBLY SPECIAL TOOL 6310–1 PRESS BLOCKS OUTPUT SHAFT
Fig. 38 Installing Fifth Gear Synchro Ring 1 – FIFTH-SPEED SYNCHRO RING 2 – FIFTH-REVERSE SYNCHRO ASSEMBLY
(11) Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft (Fig. 39). Be sure bearing is properly seated after installation.
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 39 Installing Fifth Gear Bearing 1 – SHAFT SHOULDER 2 – FIFTH GEAR BEARING
(12) Install fifth gear on shaft and onto bearing (Fig. 40).
Fig. 41 Installing Output Shaft Bearing Snap Ring 1 – BEARING SNAP RING 2 – HEAVY DUTY SNAP RING PLIERS
(16) Install first gear bearing on output shaft (Fig. 42). Be sure bearing is seated on shaft shoulder and is properly joined.
Fig. 40 Fifth Gear Installation 1 – FIFTH GEAR 2 – BEARING
(13) Install output shaft bearing. (14) Install output shaft bearing snap ring (Fig. 41). Use heavy duty snap ring pliers and spread snap ring only enough to install it. Be sure snap ring is completely seated in shaft groove before proceeding. (15) Invert output shaft and set the shaft in Remover 6310-1 so that fifth gear is seated on the tool (Fig. 42).
Fig. 42 First Gear Bearing Installation 1 2 3 4
– – – –
FIRST GEAR BEARING SHAFT SHOULDER SPECIAL TOOL 6310–1 PRESS BLOCKS
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DISASSEMBLY AND ASSEMBLY (Continued) (17) Install the first gear inner blocker ring onto first gear. (18) Install first gear on shaft and over bearing (Fig. 43). Make sure synchro cone is facing up as shown.
(21) Assemble 1-2 synchro hub sleeve, springs, struts and detent balls. CAUTION: The 1–2 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has a groove and offset teeth. This side is to be installed towards 1st gear (away from 2nd gear). (22) Start 1-2 synchro assembly on shaft by hand (Fig. 45). Be sure synchro sleeve is properly positioned.
Fig. 43 First Gear Installation 1 – FIRST GEAR 2 – SPECIAL TOOL 6310–1 3 – BEARING
(19) Install the first gear friction cone over the inner blocker ring. (20) Install first gear synchro/outer blocker ring over the first gear friction cone (Fig. 44).
Fig. 45 Starting 1-2 Synchro On Shaft 1 2 3 4
– – – –
1–2 SYNCHRO ASSEMBLY 1ST GEAR SPECIAL TOOL 6310–1 BE SURE THIS IS SINGLE GROOVE SIDE OF SYNCHRO SLEEVE
(23) Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 46). NOTE: The synchro hub is designed such that the press should be necessary to install the synchro assembly onto the output shaft. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.
Fig. 44 First Gear Synchro Ring Installation 1 – FIRST GEAR SYNCHRO RING 2 – SPECIAL TOOL 6310–1 3 – FIRST GEAR
CAUTION: Take time to align the synchro ring and sleeve as hub the is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 47 Installing 1-2 Synchro Hub Snap Ring 1 – 1–2 SYNCHRO 2 – SPECIAL TOOL 6310–1 3 – SYNCHRO SNAP RING
Fig. 46 Pressing 1-2 Synchro Assembly Onto Output Shaft 1 2 3 4 5
– – – – –
SUITABLE SIZE PIPE TOOL SYNCHRO RING SPECIAL TOOL 6310–1 1–2 SYNCHRO ASSEMBLY PRESS RAM
(24) Install new 1-2 synchro hub snap ring (Fig. 47) as follows: (a) Install thickest snap ring that will fit in shaft groove. (b) Verify that snap ring is completely seated in groove before proceeding. (25) Install second gear synchro/outer blocker ring in 1-2 synchro hub and sleeve (Fig. 48). Be sure synchro ring is properly seated in sleeve. (26) Install the second gear friction cone into the second gear synchro/outer blocker ring. (27) Install the second gear inner blocker ring into the friction cone.
Fig. 48 Second Gear Synchro Ring Installation 1 – SECOND GEAR SYNCHRO RING 2 – 1–2 SYNCHRO 3 – SPECIAL TOOL 6310–1
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DISASSEMBLY AND ASSEMBLY (Continued) (28) Install second gear needle bearing on shaft (Fig. 49).
Fig. 51 Installing Two-Piece Thrust Washer Fig. 49 Second Gear Bearing Installation 1 – SECOND GEAR BEARING 2 – SPECIAL TOOL 6310–1
(29) Install second gear onto shaft and bearing (Fig. 50). Make sure that second gear is fully seated on synchro components.
1 – WASHER (2 HALVES) 2 – PIN RELIEF 3 – PIN
(31) Seat retaining ring around two-piece thrust washer. (32) Install third gear needle bearing on shaft (Fig. 52).
Fig. 52 Third Gear Bearing Installation 1 – THIRD GEAR BEARING
Fig. 50 Second Gear Installation 1 2 3 4
– – – –
SPECIAL TOOL 6310–1 1–2 SYNCHRO ASSEMBLY BEARING SECOND GEAR
(30) Install thrust washer pin to shaft. Install twopiece thrust washer (Fig. 51). Be sure washer halves are seated in shaft groove and that pin reliefs are positioned at washer locating pin.
(33) Install third gear on shaft and bearing (Fig. 53). (34) Install third speed synchro ring on third gear (Fig. 54). (35) Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls. CAUTION: The 3–4 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has two grooves and offset teeth. This side is to be installed towards 3rd gear (away from 4th gear).
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 53 Installing Third Gear 1 – THIRD GEAR 2 – BEARING
Fig. 55 Starting 3-4 Synchro Hub On Output Shaft 1 – GROOVED SIDE OF SLEEVE (TO FRONT) 2 – 3–4 SYNCHRO ASSEMBLY
Fig. 54 Third Speed Synchro Ring Installation 1 – THIRD SPEED SYNCHRO RING 2 – THIRD GEAR
(36) Start 3-4 synchro hub on output shaft splines by hand (Fig. 55). (37) Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 56). Make sure that the tool presses on hub as close to output shaft as possible but does not contact the shaft splines. NOTE: The synchro hub is designed such that the press should be necessary to install the synchro assembly onto the output shaft. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.
Fig. 56 Pressing 3-4 Synchro Assembly On Output Shaft 1 2 3 4
– – – –
PRESS RAM PIPE TOOL 3–4 SYNCHRO THIRD SPEED SYNCHRO RING
(38) Install 3-4 synchro hub snap ring (Fig. 57) follows: (a) Install thickest snap ring that will fit shaft groove. Use heavy duty snap ring pliers install new ring. (b) Verify that snap ring is completely seated groove before proceeding.
as in to in
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DISASSEMBLY AND ASSEMBLY (Continued) be facing first gear. Tapered side of fifth-reverse sleeve with two grooves should be facing rearward toward fifth gear. GEARTRAIN ASSEMBLY (1) Install input shaft into Support Stand 8355 (Fig. 59). (2) Install pilot bearing in input shaft (Fig. 59). NOTE: There is a correct and an incorrect way to install the pilot bearing into the input shaft. The side of the pilot bearing with the small diameter goes toward the input shaft.
Fig. 57 Installing 3-4 Synchro Hub Snap Ring 1 – 3–4 SYNCHRO HUB SNAP RING 2 – HEAVY DUTY SNAP RING PLIERS
(39) Verify correct position of synchro sleeves before proceeding with assembly operations (Fig. 58). Grooved side of 3-4 sleeve should be facing rearward toward third gear. First gear side of 1-2 sleeve should
Fig. 58 Correct Synchro Sleeve Position 1 2 3 4 5
– – – – –
2 GROOVES 1 GROOVE 2 GROOVES 4TH GEAR 3RD GEAR
6 7 8 9
– – – –
2ND GEAR 1ST GEAR REVERSE GEAR 5TH GEAR
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DISASSEMBLY AND ASSEMBLY (Continued) (4) Install assembled output shaft and geartrain in input shaft (Fig. 61). Carefully rotate output shaft until the 3–4 synchro ring seats in synchro hub and sleeve.
Fig. 59 Input Shaft and Pilot Bearing 1 – PILOT BEARING 2 – INPUT SHAFT 3 – STAND 8355
(3) Install fourth gear synchro ring on input shaft (Fig. 60).
Fig. 61 Assembled Mainshaft on Support Stand 8355 1 – MAIN SHAFT 2 – SUPPORT STAND 8355
(5) Slide countershaft into fixture slot. Verify that countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding (Fig. 62). (6) Thread one Pilot Stud 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown.
Fig. 60 Installing Fourth Gear Synchro Ring On Input Shaft 1 – 4TH GEAR SYNCHRO RING 2 – INPUT SHAFT 3 – STAND 8355
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 63 Assembling 1-2 And Fifth-Reverse Shift Forks 1 – INSERT ARM THROUGH 1–2 FORK 2 – 1–2 FORK 3 – FIFTH-REVERSE FORK
Fig. 62 Countershaft Installed On Support Stand 8355 1 – COUNTER SHAFT 2 – MAIN SHAFT 3 – SUPPORT STAND 8355
(7) Assemble 1-2 and fifth reverse-shift forks (Fig. 63). Arm of fifth-reverse fork goes through slot in 1-2 fork. (8) Install assembled shift forks in synchro sleeves (Fig. 64). Be sure forks are properly seated in sleeves. REAR HOUSING (1) Lubricate countershaft rear bearing race. (2) Install rear housing onto geartrain (Fig. 65). Be sure bearing retainer pilot stud is in correct bolt hole in housing. Also be sure countershaft and output shaft bearings are aligned in housing and on countershaft.
Fig. 64 Shift Forks Installed In Synchro Sleeves 1 – 5TH REVERSE SHIFT FORK 2 – 1–2 SHIFT FORK
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 66 Applying Sealer To Retainer And Housing Bolts 1 – MOPAR GASKET MAKER (OR LOCTITE 518) 2 – RETAINER AND HOUSING BOLTS 3 – APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK AND THREADS
Fig. 65 Rear Housing Installation 1 – REAR HOUSING 2 – SHIFT FORKS AND GEARTRAIN
(3) Seat rear housing on output shaft rear bearing and countershaft. Use plastic or rawhide mallet to tap housing into place. (4) Install the three bolts that secure rear bearing retainer to rear housing as follows: (a) Apply Mopart Gasket Maker, or equivalent, to bolt threads, bolt shanks and under bolt heads (Fig. 66). (b) Start first two bolts in retainer (Fig. 67). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer. (c) Remove Pilot Stud 8120 and install last retainer bolt (Fig. 67). (d) Tighten all three retainer bolts to 22 N·m (16 ft. lbs.) torque. NOTE: All the bolts used on the NV1500 except the reverse idler shaft bolts have O-rings to seal the bolts to the transmission case. Inspect the O-rings to ensure that they are correctly installed and are in good condition.
Fig. 67 Removing Pilot Stud Tool And Installing Retainer Bolts 1 – BEARING RETAINER BOLT 2 – SPECIAL TOOL 8120
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DISASSEMBLY AND ASSEMBLY (Continued) REVERSE IDLER (1) Remove geartrain and housing assembly from support stand with aid of helper. (2) Assemble shaft, gear, and washer (without bearing or support) and install into housing (Fig. 68). NOTE: The small shoulder on the reverse idler gear goes toward the front of the transmission.
Fig. 68 Reverse Idler Assembly 1 2 3 4 5
– – – – –
SUPPORT BEARING WASHER GEAR SHAFT
CAUTION: The transmission synchros must all be in Neutral position for proper reassembly. Otherwise, the housings, shift forks and gears can be damaged during installation of the two housings. (2) Install 3-4 shift fork in synchro sleeve (Fig. 69). Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.
Fig. 69 Installing 3-4 Shift Fork 1 – 3–4 FORK 2 – ALIGN GROOVES IN FORK ARMS
(3) Slide shift shaft through 3-4 shift fork (Fig. 70). Be sure shaft detent notches are to front.
(3) Apply Mopart Gasket Maker, or equivalent, sealer to underside of idler shaft and support bolt heads, bolt shanks and bolt threads (Fig. 66). (4) Align hole in housing with threaded hole in shaft and start shaft rear bolt a few threads. (5) Install bearing into position. (6) Install segment (Fig. 68), align housing hole with segment threaded hole, and start support bolt a few threads. (7) Tighten large idler shaft bolt to 43 N·m (31.7 ft. lbs.) torque. Tighten small idler shaft bolt to 22 N·m (16.2 ft. lbs.) torque. CAUTION: Make sure the idler shaft and support segment are properly seated and held firmly in place while tightening the shaft bolts. The segment, housing or shaft threads can be damaged if the idler shaft is allowed to shift out of position in the housing. SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET (1) Before proceeding, verify that all synchro sleeves are in Neutral position (centered on hub). Move sleeves into neutral if necessary.
Fig. 70 Shift Shaft Installation 1 – SHIFT SHAFT 2 – 3–4 FORK 3 – SHAFT DETENT NOTCHES
(4) Assemble shift shaft shift lever and bushing (Fig. 71). Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft. (5) Install assembled lever and bushing on shift shaft (Fig. 72).
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 71 Assembling Shift Shaft Lever And Bushing 1 – SHAFT LEVER 2 – LEVER BUSHING 3 – BUSHING LOCK PIN SLOT
Fig. 73 Inserting Shaft Into Lever Opening In Housing 1 – SHIFT SHAFT
(7) Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 74).
Fig. 72 Installing Shift Shaft Lever And Bushing 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. 73).
Fig. 74 Shift Socket Installation 1 – SHIFT SOCKET 2 – SHIFT SHAFT
(8) Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing. CAUTION: Correct positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 180° off. If this occurs, the transmission will have to be disassembled again to correct shaft alignment.
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DISASSEMBLY AND ASSEMBLY (Continued) (9) Select correct new roll pin for shift shaft lever (Fig. 75). Shaft lever roll pin is approximately 22 mm (7/8 in.) long. Shift socket roll pin is approximately 33 mm (1-1/4 in.) long.
(12) Before proceeding, verify that lock pin slot in lever bushing is positioned as shown (Fig. 77).
Fig. 75 Roll Pin Identification—Shaft Lever And Shift Socket 1 – SHAFT LEVER ROLL PIN 2 – SHIFT SOCKET ROLL PIN
Fig. 77 Correct Seating Of Shift Shaft Lever Roll Pin (10) Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 76).
1 – BUSHING LOCK PIN SLOT 2 – SEAT ROLL PIN FLUSH WITH LEVER
(13) Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 78).
Fig. 76 Starting Roll Pin In Shift Shaft Lever 1 – SHAFT LEVER ROLL PIN (7⁄8” LONG) 2 – LEVER AND BUSHING
(11) Seat shaft lever roll pin with pin punch (Fig. 77). CAUTION: The 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.
Fig. 78 Starting Roll Pin In Shift Socket 1 – ROLL PIN 2 – SHIFT SOCKET 3 – SHIFT SHAFT
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DISASSEMBLY AND ASSEMBLY (Continued) (14) Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation (Fig. 79).
Fig. 80 Input Shaft Bearing And Countershaft Front Bearing Identification 1 – SHIFT SHAFT BUSHING 2 – INPUT SHAFT BEARING 3 – COUNTERSHAFT FRONT BEARING RACE
Fig. 79 Seating Shift Socket Roll Pin 1 2 3 4
– – – –
PIN PUNCH SHIFT SOCKET SEAT ROLL PIN FLUSH SHIFT SOCKET
(15) Verify that notches in shift fork arms are aligned. Realign arms if necessary. FRONT HOUSING AND INPUT SHAFT BEARING RETAINER (1) If previously removed, install input shaft bearing in front housing bore (Fig. 80). Install snap ring and use plastic mallet to seat bearing. Bearing goes in from front side of housing only. (2) Apply small amount of petroleum jelly to shift shaft bushing in front housing (Fig. 81). (3) Apply 1/8 in. wide bead of Mopart Gasket Maker, or equivalent, to mating surfaces of front and rear housings (Fig. 81). (4) Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain. (5) Work front housing downward onto geartrain until seated on rear housing. CAUTION: If the front housing will not seat on the rear housing, either the shift components are not in Neutral, or one or more components are misaligned. Do not force the front housing into place. This will only result in damaged components.
Fig. 81 Applying Sealer To Front/Rear Housings 1 – HOUSING FLANGE SURFACE 2 – MOPAR GASKET MAKER (OR LOCTITE 518)
(6) Place transmission in horizontal position. (7) Apply Mopart Gasket Maker, or equivalent, to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 82).
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DISASSEMBLY AND ASSEMBLY (Continued) (8) Install and start housing attaching bolts by hand (Fig. 82). Then tighten bolts to 34 N·m (25 ft. lbs.) torque.
Fig. 82 Installing Housing Attaching Bolts 1 – HOUSING ATTACHING BOLTS (APPLY SEALER BEFOREHAND)
(9) Install shift shaft bushing lock bolt (Fig. 83). Apply Mopart Gasket Maker, or equivalent, to bolt threads, shank and underside of bolt head before installation.
(10) Remove countershaft bearing shim cap and shim. Attach a dial indicator and move countershaft front and back to measure shaft end play. The required countershaft pre-load 0.001–0.003 inches. Add this amount to the measured amount of countershaft end-play. This gives the amount of shims necessary to correctly pre-load the front and rear countershaft bearings. (11) Install the selected shims and the shim cap. Tighten shim cap bolts to 29 N·m (21.4 ft. lbs.). Verify the shim selection by rotating the input shaft by hand with the transmission in neutral. The proper torque required to rotate the input shaft and the countershaft is approximately 5–7 in.lbs.. The input shaft should therefore be easily rotated by hand. If the input shaft cannot be rotated by hand or is not smooth through several rotations, re-check the countershaft pre-load. (12) Lubricate then install shift shaft detent plunger in housing bore (Fig. 84). Lubricate plunger with petroleum jelly or gear lubricant. Be sure plunger is fully seated in detent notch in shift shaft.
CAUTION: If the lock bolt cannot be fully installed, do not try to force it into place. Either the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned.
Fig. 84 Installing Shift Shaft Detent Plunger, Spring, and Plug 1 2 3 4
Fig. 83 Installing Shift Shaft Bushing Lock Bolt 1 – SHIFT SHAFT LOCK BOLT 2 – SHAFT SOCKET
– – – –
FRONT HOUSING PLUG SPRING PLUNGER
(13) Install detent spring inside plunger (Fig. 84). (14) Install detent plug as follows: (a) Install detent plug in end of Installer 8123. (b) Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore. (c) Drive detent plug into transmission case until plug seats.
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 85 Installing Backup Light Switch 1 – BACKUP LAMP SWITCH
(15) Install backup light switch (Fig. 85). (16) Install input shaft snap ring (Fig. 86).
Fig. 87 Installing Oil Seal In Front Bearing Retainer (Typical) 1 – SPECIAL TOOL 6448 2 – FRONT BEARING RETAINER
Fig. 86 Installing Input Shaft Snap Ring 1 – INPUT SHAFT SNAP RING
(17) Install new oil seal in front bearing retainer with Installer Tool 6448 (Fig. 87). (18) Apply bead of Mopart Silicone Sealer, or equivalent, to flange surface of front bearing retainer. (19) Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 88). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer. NOTE: Be sure that no sealer gets into the oil feed hole in the transmission case or bearing retainer.
Fig. 88 Installing Input Shaft Bearing Retainer 1 – BEARING RETAINER 2 – OIL FEED
(20) Install and tighten bearing retainer bolts to 29 N·m (21.4 ft. lbs.) torque (Fig. 89). SHIFT TOWER AND LEVER ASSEMBLY (1) Apply petroleum jelly to ball end of shift lever and interior of shift socket. (2) Shift the transmission into third gear.
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 89 Installing Input Shaft Bearing Retainer Bolts 1 – BOLTS (5) 2 – BEARING RETAINER
(3) Align and install shift tower and lever assembly (Fig. 90). 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. (4) Install shift tower bolts (Fig. 91). Tighten bolts to 8.5 N·m (75.2 in. lbs.) torque.
Fig. 91 Shift Tower Bolt Installation 1 – SHIFT TOWER AND LEVER ASSEMBLY
(5) Fill transmission to bottom edge of fill plug hole with Mopart Transmission Lubricant, P/N 4761526. (6) Install and tighten fill plug to 34 N·m (25 ft. lbs.) torque. (7) Check transmission vent. Be sure vent is open and not restricted.
SPECIFICATIONS TORQUE
Fig. 90 Shift Tower Installation 1 – SHIFT TOWER AND LEVER ASSEMBLY 2 – SHIFT SOCKET 3 – SEAL
DESCRIPTION TORQUE Back up Lamp Switch . . . . . . . . 41 N·m (30 ft. lbs.) Bearing Shim Cap (countershaft) . . . . . . . . 41 N·m (30 ft. lbs.) Bearing Retainer (front) . . . . . . 41 N·m (30 ft. lbs.) Bearing Retainer (rear) . . . . . . . 34 N·m (25 ft. lbs.) Drain/Fill Plug . . . . . . . . . . . . . 34 N·m (25 ft. lbs.) Shift Shaft Lock Bolt . . . . . . . . . 27 N·m (20 ft. lbs.) Shift Tower Bolts . . . . . . . . . . 14 N·m (120 in. lbs.) Idler Shaft Bolt (M8 x 1.25 x 70) . . . . . . . . . 27 N·m (20 ft. lbs.) Idler Shaft Bolt (M10 x 1.5 x 35) . . . . . . . . . 52 N·m (40 ft. lbs.)
