2001 Dodge RAM 3500 PICKUP

Size: px
Start display at page:

Download "2001 Dodge RAM 3500 PICKUP"

Transcription

1 1 of 76 9/14/2012 7:02 PM 2001 Dodge RAM 3500 PICKUP Submodel: Engine Type: L6 Liters: 5.9 Fuel Delivery: FI Fuel: DIESEL Subarticles MANUAL- NV DISASSEMBLY MANUAL- NV DISASSEMBLY MANUAL - NV ASSEMBLY DISASSEMBLY FRONT HOUSING Shift transmission into Neutral. If lubricant was not drained out of transmission during removal, remove drain plug and drain lubricant. Inspect drain plug magnet for debris. Remove backup light switch located on passenger side of rear housing Backup Light Switch. Backup Light Switch 1 - BACKUP LIGHT SWITCH 5. Remove shift tower bolts and remove tower and lever assembly Shift Tower. Shift Tower

2 2 of 76 9/14/2012 7:02 PM 1 - SHIFT TOWER AND LEVER ASSEMBLY 2 - SHIFT SOCKET 3 - SEAL 6. Remove shift shaft lock bolt Shift Shaft Lock Bolt. 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. Shift Shaft Lock Bolt 1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET 7. Remove bolts attaching input shaft bearing retainer to front housing and remove retainer. Important: Use pry tool to carefully lift retainer and break sealer bead Loosening Bearing. Loosening Bearing 1 - PRY TOOL 2 - INPUT SHAFT BEARING RETAINER 8. Remove bearing retainer from input shaft Input Shaft Bearing Retainer.

3 3 of 76 9/14/2012 7:02 PM Input Shaft Bearing Retainer 1 - SHAFT BEARING 2 - BEARING RETAINER 3 - INPUT SHAFT 9. Remove snap ring that secures input shaft in front bearing Input Shaft. Input Shaft 1 - INPUT SHAFT SNAP RING 2 - OIL FEED Remove shift shaft detent plug with Remover 8117A. Attach fingers of the remover to the detent plug and push the cup down till it contacts the trans. Then tighten the nut till it pulls the plug from the case. Remove shift shaft detent plunger and spring with a pencil magnet. Remove bolts that attach front housing to rear housing Housing And Bearing Retainer Bolt. 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.

4 4 of 76 9/14/2012 7:02 PM Housing And Bearing Retainer Bolt 1 - RETAINER BOLTS 2 - HOUSING BOLTS 3 - RETAINER BOLT 4 - HOUSING BOLT LOCATIONS 13. Separate front housing from rear housing Front Housing. Use plastic hammer to tap front housing off alignment dowels. Front Housing 1 - FRONT HOUSING 2 - REAR HOUSING 3 - DOWELS (2)

5 5 of 76 9/14/2012 7:02 PM 4 - PLASTIC MALLET 14. Remove and inspect input shaft bearing. Inspect countershaft front bearing race Input Shaft Bearing and Countershaft Front Bearing Race. Input Shaft Bearing and Countershaft Front Bearing Race 1 - INPUT SHAFT BEARING 2 - FRONT HOUSING 3 - COUNTERSHAFT FRONT BEARING 15. Note position of input shaft, shift shaft and forks, and geartrain components in housing Geartrain And Shift Components. Geartrain And Shift Components 1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER AND SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT

6 ANUAL - NV DISASSEMBLY AND ASSEMBLY 6 of 76 9/14/2012 7:02 PM FORK 8 - INPUT SHAFT FORK SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT Unseat shift socket roll pin with Remover Position remover on shift shaft and center tool over the roll pin. Verify tool legs are firmly seated on the shift socket Shift Socket. Shift Socket 1 - REMOVER SHIFT SOCKET Tilt socket toward the side of the case to avoid trapping the pin between the gear teeth. Tighten remover to press the roll pin downward and out of the shift socket Shift Socket. Shift Socket 1 - REMOVER SHIFT SOCKET Important: Roll pin does not have to be completely removed, the pin must only be clear of the shift shaft. Be careful not to push the pin into the geartrain. Drive out shift bushing and lever roll pint with a hammer and punch Shift Shaft Lever And Bushing Roll Pin.

7 7 of 76 9/14/2012 7:02 PM Shift Shaft Lever And Bushing Roll Pin 1 - PIN PUNCH 2 - BUSHING AND LEVER 3 - SHIFT SHAFT Important: Use proper size punch to avoid bending the shift shaft. Pull shift shaft straight out of rear housing, shift socket, fifth-reverse fork and 1-2 fork Shift Shaft. Shift Shaft 1 - SHIFT SHAFT FORK 3 - SHAFT DETENT NOTCHES 2. Remove shift socket from rear housing Shift Socket And Roll.

8 8 of 76 9/14/2012 7:02 PM Shift Socket And Roll 1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET 3. Remove lever and bushing Shift Shaft Lever And Bushing. Shift Shaft Lever And Bushing 1 - SHAFT LEVER AND BUSHING FORK 4. 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 3-4 Shift Fork. 3-4 Shift Fork

9 9 of 76 9/14/2012 7:02 PM FORK AND 5TH-REVERSE FORK ARMS SYNCHRO SLEEVE

10 ANUAL - NV DISASSEMBLY AND ASSEMBLY 10 of 76 9/14/2012 7:02 PM 5. Remove the reverse idler shaft support bolt (front bolt) Reverse Idler Shaft/Support. Reverse Idler Shaft/Support 1 - SUPPORT BOLT 2 - SHAFT BOLT 6. Loosen rear reverse idler shaft bolt (rear bolt) Reverse Idler Shaft/Support. Reverse Idler Shaft/Support 1 - SUPPORT BOLT 2 - SHAFT BOLT Remove reverse idler shaft support segment by sliding it straight out of housing. Support geartrain and rear housing on Fixture 6747 as follows: Adjust height of reverse idler pedestal rod until the reverse idle shaft bottoms in Cup Position Adapters A and B on Fixture Slide fixture tool onto input shaft, countershaft and idler gear Fixture Assembly.

11 11 of 76 9/14/2012 7:02 PM Fixture Assembly 1 - FIXTURE ADAPTER A 3 - CUP REVERSE IDLER PEDESTAL 5 - ADAPTER B 4. Stand geartrain and rear housing upright on fixture Geartrain And Housing Mounted On Fixture. Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position. Geartrain And Housing Mounted On Fixture 1 - INPUT SHAFT 2 - COUNTERSHAFT

12 ANUAL - NV DISASSEMBLY AND ASSEMBLY 12 of 76 9/14/2012 7:02 PM 3 - FIXTURE Remove rear bolt holding reverse idler shaft in housing. REAR HOUSING - 2WD On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case Output Shaft. Bolts are rear of shift tower opening. Output Shaft 1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT IS AT OPPOSITE SIDE OF CASE) 2. Unseat output shaft bearing from bearing bore in rear housing. With a plastic/rawhide hammer tap rear housing upward and off output shaft bearing Seperate Rear Housing From Output Shaft Bearing - 2WD.

13 ANUAL - NV DISASSEMBLY AND ASSEMBLY 13 of 76 9/14/2012 7:02 PM Seperate Rear Housing From Output Shaft Bearing - 2WD 1 - REAR HOUSING 2 - PLASTIC OR RAWHIDE MALLET 3 - FIXTURE Lift rear housing up and off geartrain Rear Housing - 2WD.

14 14 of 76 9/14/2012 7:02 PM Rear Housing - 2WD 1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN 4. Remove countershaft rear bearing from countershaft Countershaft Rear Bearing. Countershaft Rear Bearing 1 - COUNTERSHAFT REAR BEARING 2 - OUTPUT SHAFT 3 - COUNTER SHAFT 5. Examine condition of bearing bore and idler shaft notch in rear housing. Replace housing if any of these components are damaged. REAR ADAPTER HOUSING - 4WD

15 15 of 76 9/14/2012 7:02 PM Locate dimples in face of rear seal Dimples In Seal Face - 4WD. With a slide hammer mounted screw remove seal by inserting screw into seal at dimple locations Rear Seal - 4WD. Dimples In Seal Face - 4WD 1 - LOCATION OF DIMPLES 2 - SEAL FACE Rear Seal - 4WD 1 - SLIDE HAMMER 2 - REMOVER TOOL 3 - REAR SEAL 2. Remove rear bearing snap ring from output shaft with snap ring pliers Rear Bearing Snap Ring - 4WD.

16 ANUAL - NV DISASSEMBLY AND ASSEMBLY 16 of 76 9/14/2012 7:02 PM Rear Bearing Snap Ring - 4WD 1 - HEAVY DUTY SNAP RING PLIERS 2 - REAR BEARING SNAP RING 3 - OUTPUT SHAFT 3. Lift rear adapter housing upward and off geartrain Rear Adapter Housing. Rear Adapter Housing 1 - REAR ADAPTER HOUSING 2 - OUTPUT SHAFT 4. Remove bearing retainer bolts and remove rear bearing retainer and rear bearing Rear Adapter Housing Components. Use hammer handle to push or tap bearing out of housing if needed.

17 ANUAL - NV DISASSEMBLY AND ASSEMBLY 17 of 76 9/14/2012 7:02 PM Rear Adapter Housing Components 1 - BEARING RETAINER 2 - RETAINER BOLTS (3) 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT REAR BEARING RACE 5 - REAR BEARING 5. Examine condition of bearing bore, countershaft rear bearing race and idler shaft notch in rear housing. Replace housing if race, bore or notch are worn or damaged. GEARTRAIN FROM FIXTURE Remove reverse idler gear assembly from assembly fixture cup. Remove 1-2 and fifth-reverse forks from synchro sleeves. Slide countershaft out of fixture tool. Remove output shaft bearing retainer from rear surface of fifth gear (retainer will drop onto gear after bolts are removed). Lift and remove output shaft and gears off input shaft. Lift and remove input shaft, pilot bearing and fourth gear synchro ring from assembly fixture tool. OUTPUT SHAFT Important: The synchronizer hubs and sleeves are different and must not be intermixed. Remove each synchronizer unit as an assembly to avoid intermixing parts. Mark each synchro hub and sleeve with a scriber or paint for correct assembly reference Remove snap ring that secures 3-4 synchro hub on output shaft. Remove 3-4 synchro assembly, third gear synchro ring and third gear with shop press and Bearing Splitter Position splitter between second and third gears. Remove third gear needle bearing Third Gear Needle Bearing.

18 ANUAL - NV DISASSEMBLY AND ASSEMBLY 18 of 76 9/14/2012 7:02 PM Third Gear Needle Bearing 1 - THIRD GEAR NEEDLE BEARING 4. Remove retaining ring that secures two-piece thrust washer on shaft with a small pry tool Thrust Washer. Thrust Washer 1 - PRY TOOL 2 - THRUST WASHER RETAINING RING 5. Remove two-piece thrust washer Two-Piece Thrust Washer. Note position of washer locating lugs in shaft notches for installation reference.

19 19 of 76 9/14/2012 7:02 PM Two-Piece Thrust Washer 1 - SECOND GEAR 2 - THRUST WASHER (2-PIECE) 3 - WASHER LOCATING LUG 6. Remove second gear and needle bearing Second Gear. Second Gear 1 - SECOND GEAR 2 - SECOND GEAR NEEDLE BEARING 7. Remove second gear synchro ring, synchro friction cone, and synchro cone Second Gear Synchro Ring And Cones.

20 ANUAL - NV DISASSEMBLY AND ASSEMBLY 20 of 76 9/14/2012 7:02 PM Second Gear Synchro Ring And Cones SYNCHRO HUB AND SLEEVE 2 - INTERM RING 3 - SYNCHRO FRICTION CONE 4 - SYNCHRO CONE 5 - SYNCHRO RING Remove interm ring. Remove 1-2 synchro hub snap ring. Remove 1-2 synchro hub and sleeve and first gear from output shaft with shop press and Bearing Splitter 1130 Hub Sleeve And 1-2 Synchro. Position splitter between first and reverse gears. Hub Sleeve And 1-2 Synchro SYNCHRO HUB AND SLEEVE 2 - SPLITTER Remove first gear needle bearing First Gear Needle Bearing.

21 21 of 76 9/14/2012 7:02 PM First Gear Needle Bearing 1 - FIRST GEAR NEEDLE BEARING 12. Remove output shaft bearing snap ring Output Shaft Bearing Snap Ring. Output Shaft Bearing Snap Ring 1 - OUTPUT SHAFT BEARING 2 - BEARING SNAP RING 3 - SNAP RING PLIERS On 2-wheel drive models, remove output shaft bearing. Remove fifth gear Fifth Gear. Fifth Gear

22 22 of 76 9/14/2012 7:02 PM 1 - FIFTH GEAR AND SYNCHRO RING

23 23 of 76 9/14/2012 7:02 PM 15. Remove fifth gear needle bearing, spreading bearing apart just enough to clear shoulder on output shaft Fifth Gear Needle. Fifth Gear Needle 1 - FIFTH GEAR NEEDLE BEARING 16. Remove fifth-reverse synchro hub snap ring Fifth-Reverse. Fifth-Reverse 1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 2 - SYNCHRO HUB SNAP RING 3 - SNAP RING PLIERS 17. Remove fifth-reverse synchro hub and sleeve with shop press Fifth-Reverse Synchro.

24 ANUAL - NV DISASSEMBLY AND ASSEMBLY 24 of 76 9/14/2012 7:02 PM Fifth-Reverse Synchro 1 - PRESS 2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 3 - REVERSE GEAR 4 - OUTPUT SHAFT 18. Remove reverse gear and needle bearing Reverse Gear And Needle Bearing. Reverse Gear And Needle Bearing 1 - REVERSE GEAR AND NEEDLE BEARING REVERSE IDLER Remove idler gear snap rings Reverse Idler Components.

25 ANUAL - NV DISASSEMBLY AND ASSEMBLY 25 of 76 9/14/2012 7:02 PM Reverse Idler Components 1 - SNAP RING 2 - FLAT WASHER 3 - WAVE WASHER 4 - THRUST WASHER 5 - REVERSE IDLER GEAR 6 - IDLER GEAR BEARING 7 - IDLER SHAFT 8 - THRUST WASHER 9 - SNAP RING 10 - THRUST WASHER LOCKBALLS Remove thrust washer, wave washer, thrust plate and idler gear from shaft. Remove idler gear needle bearing from shaft. ASSEMBLY Gaskets are not used in this transmission. Sealers are used at all case joints. Recommended sealers are Mopar Gasket Maker for all case joints and Mopar silicone sealer, or equivalent, for the input shaft bearing retainer. Apply these products as indicated in the assembly procedures. Important: The transmission shift components must be in Neutral position during assembly. This prevents damaging to the synchro and shift components when the housings are installed. The 3-4, 1-2 and fifth-reverse synchro hub snap rings can be fitted selectively. New snap rings are available in 0.05 mm ( in.) thickness increments. Use thickest snap ring that will fit in each snap ring groove. SYNCHRONIZER To assemble each synchro install the springs, struts and detent balls one at a time as follows: Slide sleeve part way onto the hub. Leave enough room to install the spring in the hub and the strut in the hub groove. Install first spring in the hub, then install a strut over the spring. Verify spring is seated in the spring bore in the strut. Slide sleeve onto the hub just far enough to hold the first strut and spring in place. Place 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. Repeat 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. Verify the synchro three springs, struts and detent balls are all in place Synchronizer Components.

26 ANUAL - NV DISASSEMBLY AND ASSEMBLY 26 of 76 9/14/2012 7:02 PM Synchronizer Components 1 - SLEEVE 2 - HUB SHOULDER 3 - SPRING (3) 4 - STRUT (3) 5 - DETENT BALL (3) 6 - HUB OUTPUT SHAFT Important: Lubricate shaft, gears and bearings with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place. Immerse each synchro ring in lubricant before installation. Lubricate and install reverse gear needle bearing on shaft Reverse Gear Bearing. Slide bearing up against shoulder on output shaft. Reverse Gear Bearing 1 - REVERSE GEAR BEARING 2 - SHOULDER 2. Install reverse gear over needle bearing Reverse Gear.

27 27 of 76 9/14/2012 7:02 PM Reverse Gear 1 - REVERSE GEAR 3. Install brass synchro ring on reverse gear Reverse Gear Synchro. Reverse Gear Synchro 1 - REVERSE GEAR 2 - SYNCHRO RING 4. Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done. Caution: One side of the hub has shoulders around the hub bore, this side of the hub faces the front of the shaft. One side of the sleeve is tapered the tapered side faces the front of the shaft. Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover Fifth- Reverse Synchro Assembly.

28 28 of 76 9/14/2012 7:02 PM Fifth-Reverse Synchro Assembly 1 - SPACER 2 - PRESS RAM 3 - REVERSE GEAR 4 - FIFTH-REVERSE SYNCHRO ASSEMBLY 5 - REMOVER PRESS BLOCKS 7 - OUTPUT SHAFT 2. Install the thickest newfifth-reverse hub snap ring Fifth-Reverse Synchro Hub Snap Ringthat will fit in shaft groove. Verify snap ring is seated in the groove. Fifth-Reverse Synchro Hub Snap Ring 1 - FIFTH-REVERSE SYNCHRO ASSEMBLY 2 - SNAP RING 3 - PRESS BED

29 29 of 76 9/14/2012 7:02 PM 4 - PRESS BLOCKS Important: Snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to in.). Install fifth gear synchro ring in synchro hub and sleeve Fifth Gear Synchro Ring. Fifth Gear Synchro Ring 1 - FIFTH-SPEED SYNCHRO RING 2 - FIFTH-REVERSE SYNCHRO ASSEMBLY 2. Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft Fifth Gear Bearing. Verify bearing is properly seated. Fifth Gear Bearing 1 - SHAFT SHOULDER 2 - FIFTH GEAR BEARING 3. Install fifth gear on shaft and onto bearing Fifth Gear.

30 30 of 76 9/14/2012 7:02 PM Fifth Gear 1 - FIFTH GEAR 2 - BEARING 4. Invert output shaft and set the shaft in Special Tool so that fifth gear is seated on the tool First Gear. First Gear 1 - FIRST GEAR BEARING 2 - SHAFT SHOULDER 3 - SPECIAL TOOL PRESS BLOCKS 5. Install first gear bearing on output shaft First Gear. Verify bearing is seated on shaft shoulder and is properly joined.

31 31 of 76 9/14/2012 7:02 PM First Gear 1 - FIRST GEAR BEARING 2 - SHAFT SHOULDER 3 - SPECIAL TOOL PRESS BLOCKS 6. Install first gear on shaft and over bearing First Gear. Verify bearing synchro cone is facing up as shown. First Gear 1 - FIRST GEAR 2 - SPECIAL TOOL BEARING 7. Install first gear synchro ring First Gear Synchro Ring.

32 ANUAL - NV DISASSEMBLY AND ASSEMBLY 32 of 76 9/14/2012 7:02 PM First Gear Synchro Ring 1 - FIRST GEAR SYNCHRO RING 2 - SPECIAL TOOL FIRST GEAR 8. Assemble 1-2 synchro hub sleeve, springs, struts and detent balls. Caution: One side of the synchro sleeve is marked First Gear Side. This side of the sleeve must face first gear after installation. Start 1-2 synchro assembly on shaft by hand Starting 1-2 Synchro. Verify synchro sleeve is properly positioned. Starting 1-2 Synchro SYNCHRO ASSEMBLY 2 - SPECIAL TOOL FIRST GEAR SIDE 2. Press 1-2 synchro onto output shaft using suitable size pipe and shop press Press 1-2 Synchro On Output Shaft.

33 33 of 76 9/14/2012 7:02 PM Press 1-2 Synchro On Output Shaft 1 - PIPE TOOL 2 - SYNCHRO RING 3 - SPECIAL TOOL SYNCHRO ASSEMBLY 5 - PRESS RAM Caution: Carefully 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. 2. Install interm ring. Install thickest new1-2 synchro hub snap ring 1-2 Synchro Hub Snap Ringthat will fit in shaft groove. Verify snap ring is seated in shaft groove. 1-2 Synchro Hub Snap Ring

34 34 of 76 9/14/2012 7:02 PM SYNCHRO 2 - SPECIAL TOOL SYNCHRO SNAP RING

35 35 of 76 9/14/2012 7:02 PM Important: Snap rings are available in thicknesses from 80 mm to 2.00 mm (0.070 to in.). Install second gear synchro ring in 1-2 synchro hub and sleeve Second Gear Synchro Ring. Verify synchro ring is seated in sleeve. Second Gear Synchro Ring 1 - SECOND GEAR SYNCHRO RING SYNCHRO 3 - SPECIAL TOOL Install synchro friction cone and synchro cone in synchro ring. Install second gear needle bearing on shaft Second Gear Bearing. Second Gear Bearing 1 - SECOND GEAR BEARING 2 - SPECIAL TOOL

36 36 of 76 9/14/2012 7:02 PM 4. Install second gear onto shaft and bearing Second Gear. Verify second gear is seated on synchro components. Second Gear 1 - SPECIAL TOOL SYNCHRO ASSEMBLY 3 - BEARING 4 - SECOND GEAR 5. Install two-piece thrust washer with halves seated in the shaft groove and washer lugs seated in shaft lug bores Two-Piece Thrust. Verify i.d. grooves and markings noted during removal are facing the correct direction.

37 37 of 76 9/14/2012 7:02 PM Two-Piece Thrust 1 - WASHER GROOVE IN SHAFT 2 - LUG BORE 3 - THRUST WASHER LUGS 4 - LUG BORE 5 - LUG 6 - WASHER HALF 6. Start retaining ring around two-piece thrust washer Retaining Ring. Verify locating dimple is between thrust washer halves. Retaining Ring 1 - THRUST WASHER RETAINING RING 2 - THRUST WASHER HALVES 3 - SECOND GEAR 4 - LOCATING DIMPLE 7. Seat thrust washer retaining ring with plastic mallet Thrust Retainer. Thrust Retainer

38 38 of 76 9/14/2012 7:02 PM 1 - PLASTIC MALLET 2 - THRUST WASHER RETAINING RING

39 39 of 76 9/14/2012 7:02 PM 8. Install third gear needle bearing on shaft Third Gear Bearing. Third Gear Bearing 1 - THIRD GEAR BEARING 9. Install third gear on shaft and bearing Third Gear. Third Gear 1 - THIRD GEAR 2 - BEARING 10. Install third speed synchro ring on third gear Third Gear Synchro Ring.

40 40 of 76 9/14/2012 7:02 PM Third Gear Synchro Ring 1 - THIRD SPEED SYNCHRO RING 2 - THIRD GEAR 1 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 grooves in it, this side of sleeve faces the front of the shaft. Start 3-4 synchro hub on output shaft splines by hand 3-4 Synchro Hub On Output Shaft. 3-4 Synchro Hub On Output Shaft 1 - GROOVED SIDE OF SLEEVE SYNCHRO ASSEMBLY 2. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe Press 3-4 Synchro On Output Shaft. Verify tool presses on hub as close to output shaft as possible but does not contact the shaft splines.

41 ANUAL - NV DISASSEMBLY AND ASSEMBLY 41 of 76 9/14/2012 7:02 PM Press 3-4 Synchro On Output Shaft 1 - PRESS RAM 2 - PIPE TOOL SYNCHRO 4 - THIRD SPEED SYNCHRO RING 3. Install thickest new3-4 synchro hub snap ring 3-4 Synchro Hub Snap Ringthat will fit in shaft groove. Verify snap ring is seated in groove. 3-4 Synchro Hub Snap Ring SYNCHRO HUB SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS Important: Snap rings are available in thicknesses from mm ( in.). 2. Install output shaft bearing. Install output shaft bearing snap ring with heavy duty snap ring pliers Output Shaft Bearing Snap. Verify snap ring is seated in shaft groove.

42 ANUAL - NV DISASSEMBLY AND ASSEMBLY 42 of 76 9/14/2012 7:02 PM Output Shaft Bearing Snap 1 - BEARING SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS Important: Spread snap ring only enough to install it. Verify position of synchro sleeves before proceeding Synchro Sleeve Locations. Grooved side of 3-4 sleeve must be facing forward. First gear side of 1-2 sleeve must be facing first gear. Tapered side of fifth-reverse sleeve must be facing forward. Synchro Sleeve Locations 1 - DOUBLE GROOVE FORWARD 2 - GROOVE FORWARD 3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 4 - TAPER FORWARD 5 - GROOVE FORWARD 6-5TH-REV SYNCHRO SLEEVE SYNCHRO SLEEVE SYNCHRO SLEEVE REVERSE IDLER ASSEMBLY 2. Lubricate idler components with gear lube. Slide idler gear bearing on shaft Idler Gear And Bearing. Bearing fits either way on shaft.

43 43 of 76 9/14/2012 7:02 PM Idler Gear And Bearing 1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT 3. Slide gear onto shaft. Side of gear with recess goes to rear Idler Gear And Bearing. Idler Gear And Bearing 1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT 4. Place first lock ball in dimple at rear end of idler shaft Idler Gear And Bearing. Petroleum jelly can be used to hold ball in place if desired.

44 44 of 76 9/14/2012 7:02 PM Idler Gear And Bearing 1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT 5. Slide thrust rear thrust washer onto shaft and over lock ball Idler Gear Rear Thrust Washer. Idler Gear Rear Thrust Washer 1 - LOCK BALL 2 - SNAP RING GROOVE 3 - THRUST WASHER 6. Install snap ring in groove at rear of shaft Idler Gear Rear Thrust Washer.

45 45 of 76 9/14/2012 7:02 PM Idler Gear Rear Thrust Washer 1 - LOCK BALL 2 - SNAP RING GROOVE 3 - THRUST WASHER Install lock ball in dimple at front of shaft. Hold ball in place with petroleum jelly if desired. Install front thrust washer on shaft and slide washer up against gear and over lock ball Idler Gear And Shaft Assembly. Idler Gear And Shaft Assembly 1 - REAR OF SHAFT 2 - GEAR 3 - THRUST WASHER AND BALL 4 - WAVE WASHER 5 - FLAT WASHER 6 - FRONT OF SHAFT

46 46 of 76 9/14/2012 7:02 PM 7 - SNAP RING 8 - SNAP RING 9. Install wave washer, flat washer and remaining snap ring on idler shaft Idler Gear And Shaft Assembly. Verify snap ring is seated. Idler Gear And Shaft Assembly 1 - REAR OF SHAFT 2 - GEAR 3 - THRUST WASHER AND BALL 4 - WAVE WASHER 5 - FLAT WASHER 6 - FRONT OF SHAFT 7 - SNAP RING 8 - SNAP RING SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS 2. Inspect shift shaft bushing and bearing for damage. If necessary, the shift shaft bushing can be replaced as follows: 3. Locate a bolt that will thread into the bushing without great effort. 2. Thread the bolt into the bushing, allowing the bolt to make its own threads in the bushing. 3. Attach a slide hammer or suitable puller to the bolt and remove bushing. 4. Use the short end of Installer 8119 to install the new bushing. 5. Bushing is correctly installed if flush with the transmission case. If necessary, the shift shaft bearing can be replaced as follows: Locate a bolt that will thread into the bearing without great effort. Thread the bolt into the bearing as much as possible. Attach a slide hammer or suitable puller to the bolt and remove the bearing.

47 47 of 76 9/14/2012 7:02 PM Use the short end of Installer 8119 to install the new bearing. 5. Bearing is correctly installed if flush with the transmission case. Inspect detent plunger bushings for damage. Important: The detent plunger bushings are installed to a specific depth. The space between the two bushings when correctly installed contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted. If necessary, the detent plunger bushings can be replaced as follows: Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore. Remove the bushings from the shift shaft bore. Install a new detent plunger bushing on the long end of Installer Start bushing in the detent plunger bore in the case. Drive bushing into the bore until the tool contacts the transmission case. Install a new detent plunger bushing on the short end of Installer Start the bushing in the detent plunger bore in the case. Drive bushing into the bore until the tool contacts the transmission case. GEARTRAIN ASSEMBLY Install Adapter A on input shaft hub of Fixture 6747 Fixture For Geartrain Build-up. Then install Adapter B on front bearing hub of countershaft. Be sure the shoulder is seated against the countershaft. Fixture For Geartrain Build-up 1 - ADAPTER B 2 - CUP ADAPTER A 4 - FIXTURE Install input shaft in fixture tool. Make sure Adapter Tool A is positioned under shaft as shown Pilot Bearing And Input Shaft.

48 ANUAL - NV DISASSEMBLY AND ASSEMBLY 48 of 76 9/14/2012 7:02 PM Pilot Bearing And Input Shaft 1 - PILOT BEARING 2 - INPUT SHAFT 3. Install pilot bearing in input shaft Pilot Bearing And Input Shaft. Pilot Bearing And Input Shaft 1 - PILOT BEARING 2 - INPUT SHAFT Important: The side of the pilot bearing with the small diameter goes toward the input shaft. 4. Install fourth gear synchro ring on input shaft Fourth Gear Synchro.

49 49 of 76 9/14/2012 7:02 PM Fourth Gear Synchro 1 - FOURTH GEAR SYNCHRO RING 2 - INPUT SHAFT 5. Adjust height of idler gear pedestal on assembly fixture Idler Pedestal Base Height. Start with a basic height of 18.4 cm (7-1/4 in.). Final adjustment can be made after gear is positioned on pedestal. Idler Pedestal Base Height 1 - REVERSE IDLER PEDESTAL 6. Install assembled output shaft and geartrain in input shaft Output Shaft And Geartrain Installed In Input. Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.

50 50 of 76 9/14/2012 7:02 PM Output Shaft And Geartrain Installed In Input 1 - OUTPUT SHAFT AND GEARTRAIN 2 - INPUT SHAFT 3 - FIXTURE Install Adapter B on front bearing hub of countershaft, if not previously done. The shoulder goes toward the countershaft. Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding Countershaft On Fixture Tool.

51 51 of 76 9/14/2012 7:02 PM Countershaft On Fixture Tool 1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL) Check alignment of countershaft and output shaft gear teeth. Gears may not align perfectly a difference in height of 57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This difference will not interfere with assembly. If difference is greater than this, the countershaft adapter tool is probably upside down. Remove countershaft, reverse adapter tool, reinstall countershaft and check alignment again. Position reverse idler in support cup of assembly fixture Reverse Idler Assembly On Assembly Fixture Tool. Verify idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out from the geartrain. Adjust pedestal up or down if necessary and verify short end of idler shaft is facing up as shown.

52 52 of 76 9/14/2012 7:02 PM Reverse Idler Assembly On Assembly Fixture Tool 1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT 3 - REVERSE IDLER ASSEMBLY 4 - TOOL PEDESTAL 1 On 2-wheel drive transmission, thread one Alignment Pin 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown Positioning Output Shaft Bearing Retainer. Positioning Output Shaft Bearing Retainer 1 - PIN OUTPUT SHAFT BEARING RETAINER 12. Assemble 1-2 and fifth reverse-shift forks 1-2 And Fifth-Reverse Shift Forks. Arm of fifth-reverse fork goes through slot in 1-2 fork.

53 53 of 76 9/14/2012 7:02 PM 1-2 And Fifth-Reverse Shift Forks 1 - INSERT ARM THROUGH 1-2 FORK FORK 3 - FIFTH-REVERSE FORK 13. Install assembled shift forks in synchro sleeves and verify forks are seated in sleeves Shift Forks In Synchro. Shift Forks In Synchro 1 - SYNCHRO SLEEVES 2 - FORK ARMS 3 - SHIFT FORKS REAR HOUSING - 2WD Drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface Rear Housing Dowels.

54 54 of 76 9/14/2012 7:02 PM Rear Housing Dowels 1 - HOUSING ALIGNMENT DOWELS 2 - REAR HOUSING 3 - DOWEL FLUSH WITH SURFACE Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race. Install countershaft rear bearing in bearing race Countershaft Rear. Countershaft Rear 1 - COUNTERSHAFT REAR BEARING 2 - REAR BEARING RACE 3 - REAR HOUSING 4 - PETROLEUM JELLY (APPLY TO BEARING AND RACE)

55 55 of 76 9/14/2012 7:02 PM Important: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing Countershaft Bearing. Countershaft Bearing 1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE) 2. Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed. Apply light coat of petroleum jelly to shift shaft bushing/bearing in rear housing Countershaft Bearing. Countershaft Bearing 1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE) Reach into countershaft rear bearing with finger and push each bearing roller outward against the race. Then apply extra petroleum jelly to hold rollers in place during housing installation. Install rear housing onto geartrain Rear Housing - 2WDand verify bearing retainer pilot stud is in correct bolt hole in housing. Be sure countershaft and output shaft bearings are aligned in housing and on countershaft.

56 56 of 76 9/14/2012 7:02 PM Rear Housing - 2WD 1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN Important: It may be necessary to lift upward on countershaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages the housing. 2. Seat rear housing on output shaft rear bearing and countershaft. Use plastic or rawhide mallet to tap housing into place. Apply Mopar Gasket Maker or equivalent to housing bolt threads, bolt shanks and under bolt heads Housing Bolts. Housing Bolts

57 ANUAL - NV DISASSEMBLY AND ASSEMBLY 57 of 76 9/14/2012 7:02 PM 1 - MOPAR GASKET MAKER (OR LOCTITE 518) 2 - RETAINER AND HOUSING BOLTS 3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK AND THREADS 3. Start first two bolts in retainer Pilot Stud Tool And Retainer Bolts - 2WD. It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer. Pilot Stud Tool And Retainer Bolts - 2WD 1 - BEARING RETAINER BOLT 2 - PIN Remove Alignment Pin 8120 and install last retainer bolt Pilot Stud Tool And Retainer Bolts - 2WD. Pilot Stud Tool And Retainer Bolts - 2WD 1 - BEARING RETAINER BOLT 2 - PIN Tighten all three retainer bolts to N m (22-26 ft. lbs.). ADAPTER HOUSING - 4WD 2. Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place. Position rear bearing retainer in adapter housing Adapter Housing - 4WD.

58 58 of 76 9/14/2012 7:02 PM Adapter Housing - 4WD 1 - BEARING RETAINER 2 - RETAINER BOLT 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT BEARING RACE 5 - REAR BEARING 3. Apply Mopar Gasket Maker or equivalent to threads, bolt shanks and under hex heads of bearing retainer bolts Housing Bolts. 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

59 59 of 76 9/14/2012 7:02 PM Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race. Install countershaft rear bearing in bearing race Countershaft Bearing. Countershaft Bearing 1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE) Important: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing Countershaft Bearing. Countershaft Bearing 1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE) 2. Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed. Apply light coat of petroleum jelly to shift shaft bushing/bearing in adapter housing Countershaft Bearing.

60 60 of 76 9/14/2012 7:02 PM Countershaft Bearing 1 - SHIFT SHAFT BUSHING/BEARING 2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE) Install adapter housing on geartrain. Install rear bearing snap ring on output shaft Rear Bearing Snap Ring - 4WD. Rear Bearing Snap Ring - 4WD 1 - SNAP RING PLIERS 2 - SNAP RING 3 - OUTPUT SHAFT 5. Lubricate lip of new rear seal Rear Sealwith Mopar Door Ease, or transmission fluid.

61 61 of 76 9/14/2012 7:02 PM Rear Seal 1 - REAR SEAL 2 - SEAL LIP 3 - OUTPUT SHAFT 6. Install newrear seal in adapter housing bore with Installer C-3860-A. Verify seal is seated in housing bore Rear Seal. Rear Seal 1 - REAR SEAL 2 - SEAL LIP 3 - OUTPUT SHAFT SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET Verify that all synchro sleeves are in Neutral position (centered on hub). Caution: Transmission synchros must all be in Neutral position for reassembly. Otherwise the housings, shift forks and gears can be damaged during installation of the two housings. Install 3-4 shift fork in synchro sleeve 3-4 Shift Fork. Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.

62 62 of 76 9/14/2012 7:02 PM 3-4 Shift Fork FORK 2 - ALIGN GROOVES IN FORK ARMS 2. Slide shift shaft through 3-4 shift fork Shift Shaftwith shaft detent notches to the rear. Shift Shaft 1 - SHIFT SHAFT FORK 3 - SHAFT DETENT NOTCHES 3. Assemble shift shaft shift lever and bushing Shift Shaft Lever And Bushing. Verify slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.

63 63 of 76 9/14/2012 7:02 PM Shift Shaft Lever And Bushing 1 - SHAFT LEVER 2 - LEVER BUSHING 3 - BUSHING LOCK PIN SLOT 4. Install assembled lever and bushing on shift shaft Install Shift Shaft Lever And Bushing. Install Shift Shaft Lever And Bushing 1 - SHIFT SHAFT 2 - SHAFT LEVER AND BUSHING FORK 5. Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing Inserting Shaft Into Lever Opening.

64 64 of 76 9/14/2012 7:02 PM Inserting Shaft Into Lever Opening 1 - SHIFT SHAFT 6. Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing Shift Socket. Shift Socket 1 - SHIFT SOCKET 2 - SHIFT SHAFT 7. Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing. Caution: Both shaft roll pins can be installed when the shaft is 180 off. If this occurs, the transmission wil l have to be disassembled again to correct shaft alignment. Select correct newroll pin for shift shaft lever Roll Pin Identification. 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.

65 65 of 76 9/14/2012 7:02 PM Roll Pin Identification 1 - SHAFT LEVER ROLL PIN 2 - SHIFT SOCKET ROLL PIN 2. Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand Roll Pin In Shift Socket. Roll Pin In Shift Socket 1 - SHAFT LEVER ROLL PIN 2 - LEVER AND BUSHING 3. Seat shaft lever roll pin with pin punch Shift Shaft Lever Roll. Shift Shaft Lever Roll 1 - BUSHING LOCK PIN SLOT 2 - SEAT ROLL PIN FLUSH WITH LEVER Caution: Shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush. Verify that lock pin slot in lever bushing is positioned as shown Shift Shaft Lever Roll.

66 66 of 76 9/14/2012 7:02 PM Shift Shaft Lever Roll 1 - BUSHING LOCK PIN SLOT 2 - SEAT ROLL PIN FLUSH WITH LEVER 2. Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand Roll Pin In Shift Socket. Roll Pin In Shift Socket 1 - ROLL PIN 2 - SHIFT SOCKET 3 - SHIFT SHAFT 3. Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation Seat Shift Socket.

67 67 of 76 9/14/2012 7:02 PM Seat Shift Socket 1 - PIN PUNCH 2 - SHIFT SOCKET 3 - SEAT ROLL PIN FLUSH 4 - SHIFT SOCKET 4. Verify that notches in shift fork arms are aligned. Realign arms if necessary. FRONT HOUSING AND INPUT SHAFT BEARING RETAINER If previously removed, install input shaft bearing in front housing bore Input Shaft Bearing And Countershaft Front Bearing. Install snap ring and use plastic mallet to seat bearing. Bearing goes in from front side of housing only. Input Shaft Bearing And Countershaft Front Bearing 1 - INPUT SHAFT BEARING 2 - COUNTERSHAFT FRONT BEARING 3 - SHIFT SHAFT BUSHING

68 68 of 76 9/14/2012 7:02 PM 2. Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race Input Shaft Bearing And Countershaft Front Bearing. Large diameter side of bearing cage goes toward countershaft Countershaft Front Bearing. Small diameter side goes toward bearing race in housing. Input Shaft Bearing And Countershaft Front Bearing 1 - INPUT SHAFT BEARING 2 - COUNTERSHAFT FRONT BEARING 3 - SHIFT SHAFT BUSHING Countershaft Front Bearing 1 - BEARING RACE 2 - PETROLEUM JELLY 3 - COUNTERSHAFT FRONT BEARING Reach into countershaft front bearing with finger and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place during housing installation. Apply small amount of petroleum jelly to shift shaft bushing in front housing. Apply 1/8 in. wide bead of Mopar Gasket Maker or equivalent to mating surfaces of front and rear housings Seal Front/Rear Housings.

69 ANUAL - NV DISASSEMBLY AND ASSEMBLY 69 of 76 9/14/2012 7:02 PM Seal Front/Rear Housings 1 - HOUSING FLANGE SURFACE 2 - MOPAR GASKET MAKER (OR LOCTITE 518) Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain. Work front housing downward onto geartrain until seated on rear housing. Caution: Front housings will not seat if shift components are not in Neutral or one or more components are misaligned. Do not force the front housing into place Tap rear housing alignment dowels back into place with hammer and pin punch. Both dowels should be flush fit in each housing. Have helper hold transmission upright while dowels are tapped back into place. Place transmission in horizontal position. Apply Mopar Gasket Maker or equivalent, to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads Housing Bolts. Housing Bolts 1 - HOUSING ATTACHING BOLTS (APPLY SEALER BEFOREHAND) 4. Install and start housing attaching bolts by hand Housing Bolts. Then tighten bolts to 34 N m (25 ft. lbs.).

70 70 of 76 9/14/2012 7:02 PM Housing Bolts 1 - HOUSING ATTACHING BOLTS (APPLY SEALER BEFOREHAND) 5. Install shift shaft bushing lock bolt Shift Shaft Bushing Lock Bolt. Apply Mopar Gasket Maker or equivalent to bolt threads, shank and underside of bolt head before installation. Shift Shaft Bushing Lock Bolt 1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET Caution: If lock bolt cannot be fully installed the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned. Lubricate then install shift shaft detent plunger in housing bore Shift Shaft Detent Plunger. Lubricate plunger with petroleum jelly or gear lubricant. Verify plunger is fully seated in detent notch in shift shaft.

71 71 of 76 9/14/2012 7:02 PM Shift Shaft Detent Plunger 1 - FRONT HOUSING 2 - PLUG 3 - SPRING 4 - PLUNGER 2. Install detent spring inside plunger Shift Shaft Detent Plunger. Shift Shaft Detent Plunger 1 - FRONT HOUSING 2 - PLUG 3 - SPRING 4 - PLUNGER Install detent plug in end of Installer Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore. Drive detent plug into transmission case until plug seats. Install backup light switch Backup Light Switch.

72 72 of 76 9/14/2012 7:02 PM Backup Light Switch 1 - BACKUP LIGHT SWITCH 5. Install input shaft snap ring Shaft Snap Ring - Typical. Shaft Snap Ring - Typical 1 - INPUT SHAFT SNAP RING 6. Install newoil seal in front bearing retainer with Installer 6448 Oil Seal In Front Bearing Retainer. Oil Seal In Front Bearing Retainer

73 73 of 76 9/14/2012 7:02 PM 1 - INSTALLER FRONT BEARING RETAINER

74 74 of 76 9/14/2012 7:02 PM 7. Apply bead of Mopar silicone sealer or equivalent to flange surface of front bearing retainer Seal Bearing Retainer And Housing - Typical. Seal Bearing Retainer And Housing - Typical 1 - APPLY SEALER BEAD 2 - INPUT SHAFT BEARING RETAINER 8. Align and install front bearing retainer over input shaft and onto housing mounting surface Input Shaft Bearing Retainer. Verify bolt holes are aligned before seating retainer. Input Shaft Bearing Retainer 1 - INPUT SHAFT 2 - OIL FEED 3 - BEARING RETAINER Caution: Be sure sealer does not get into the oil feed hole in the transmission case or bearing retainer. Install and tighten bearing retainer bolts to 7-10 N m (5-7 ft. lbs.) Input Shaft Bearing Retainer Bolts - Typical.

75 75 of 76 9/14/2012 7:02 PM Input Shaft Bearing Retainer Bolts - Typical 1 - RETAINER BOLTS SHIFT TOWER AND LEVER Apply petroleum jelly to ball end of shift lever and interior of shift socket. Shift the transmission into third gear. Align and install shift tower and lever assembly Shift Tower. 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. Shift Tower 1 - SHIFT TOWER 4. Install shift tower bolts Shift Tower Boltsand tighten bolts to 8.5 N m (75.2 in. lbs.).

76 ANUAL - NV DISASSEMBLY AND ASSEMBLY 76 of 76 9/14/2012 7:02 PM Shift Tower Bolts 1 - SHIFT TOWER AND LEVER ASSEMBLY Fill transmission to bottom edge of fill plug hole with Mopar Transmission Lubricant. Install and tighten fill plug to 34 N m (25 ft. lbs.). Check transmission vent. Be sure vent is open and not restricted. Top of Page EBSCO Support Site Privacy Policy Terms of Use Copyright 2010 EBSCO Industries, Inc. All rights reserved EBSCO Publishing Green Initiatives

TRANSMISSION AND TRANSFER CASE

TRANSMISSION AND TRANSFER CASE XJ TRANSMISSION AND TRANSFER CASE 21-1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page AX5 MANUAL TRANSMISSION... 1 NV3550 MANUAL TRANSMISSION... 42 AUTOMATIC TRANSMISSION 30RH... 88 page AW 4 AUTOMATIC

More information

SPECIAL TOOLS Dodge Pickup 5.9L Eng R3500. Fig 1: Identifying Remover C-3985-B (Special Tool) 9/6/13 Printer Friendly View

SPECIAL TOOLS Dodge Pickup 5.9L Eng R3500. Fig 1: Identifying Remover C-3985-B (Special Tool) 9/6/13 Printer Friendly View Procedures 2003 Dodge Pickup 5.9L Eng R3500 manual transmission SPECIAL TOOLS Fig 1: Identifying Remover C-3985-B (Special Tool) www2.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname=

More information

DISASSEMBLY. Transmission. 2. Remove the 4 clutch housing bolts. Separate the clutch housing from the transmission.

DISASSEMBLY. Transmission. 2. Remove the 4 clutch housing bolts. Separate the clutch housing from the transmission. 308-03A-1 DISASSEMBLY Transmission 308-03A-1 Special Tool(s) Puller, Bearing 205-D064 (D84L-1123-A) or equivalent Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C) 2. Remove the 4 clutch housing

More information

Page 1 of 15 Transmission, Model S5-42 ZF Model S5-42 ZF Disassembly NOTE: For 4x4 and F-Super Duty vehicles, skip to Step 5. 1. Attach the transmission to the Bench Mounted Holding Fixture T57L-500-B

More information

TRANSMISSION AND TRANSFER CASE

TRANSMISSION AND TRANSFER CASE TJ TRANSMISSION AND TRANSFER CASE 21-1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page MANUAL TRANSMISSION - NSG370...1 AUTOMATIC TRANSMISSION - 42RLE...37 page TRANSFER CASE - NV231...165 TRANSFER

More information

TRANSMISSION AND TRANSFER CASE

TRANSMISSION AND TRANSFER CASE TRANSMISSION AND TRANSFER CASE 21-1 TRANSMISSION AND TRANSFER CASE CONTENTS page page AUTOMATIC TRANSMISSION-30/32RH...... 71 MANUAL TRANSMISSION-AX5............. 1 MANUAL TRANSMISSION-AX15...........

More information

SECTION 5B MANUAL TRANSMISSION TABLE OF CONTENTS

SECTION 5B MANUAL TRANSMISSION TABLE OF CONTENTS SECTION 5B MANUAL TRANSMISSION TABLE OF CONTENTS General Description and Operation... 5B-2 Shift Lever... 5B-2 Transmission Assembly... 5B-2 Specifications... 5B-3 Diagnostic Information and Procedures...

More information

ATTENTION ADVANCE SERVICE BULLETIN INFORMATION

ATTENTION ADVANCE SERVICE BULLETIN INFORMATION SUBJECT: NO: 21-10-98 Loss Of Fifth Gear GROUP: Transmission EFFECTIVE DATE: Sep. 11, 1998 CHRYSLER MAIL MANAGEMENT SYSTEM DATE: AUG. 28, 1998 ATTENTION ADVANCE SERVICE BULLETIN INFORMATION The following

More information

TRANSMISSION AND TRANSFER CASE

TRANSMISSION AND TRANSFER CASE DR TRANSMISSION AND TRANSFER CASE 21-1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page MANUAL TRANSMISSION- G56- SERVICE INFORMATION...1 MANUAL TRANSMISSION- GETRAG 238- SERVICEINFORMATION...69 MANUAL

More information

Transmission Overhaul Procedures-Bench Service

Transmission Overhaul Procedures-Bench Service How to Install the Auxiliary Countershaft Assembly Special Instructions To make auxiliary section assembly easier, you can make an auxiliary section fixture out of a 2" x 12" piece of wood. 3' 1' 3" 4.56"

More information

MANUAL TRANS OVERHAUL - BORG-WARNER - T56 6-SPEED MANUAL TRANSMISSIONS Borg-Warner T56 (MM6) 6-Speed

MANUAL TRANS OVERHAUL - BORG-WARNER - T56 6-SPEED MANUAL TRANSMISSIONS Borg-Warner T56 (MM6) 6-Speed IDENTIFICATION MANUAL TRANS OVERHAUL - BORG-WARNER - T56 6-SPEED 1998 MANUAL TRANSMISSIONS Borg-Warner T56 (MM6) 6-Speed Transmission has 2 identification labels, located on lower left side of case. One

More information

TRANSMISSION 6.7 GENERAL HOME. See Figure The transmission is a five-speed constantmesh type housed in an extension of the crankcase.

TRANSMISSION 6.7 GENERAL HOME. See Figure The transmission is a five-speed constantmesh type housed in an extension of the crankcase. TRANSMISSION 6.7 GENERAL See Figure 6-45. The transmission is a five-speed constantmesh type housed in an extension of the crankcase. Mainshaft Neutral Mainshaft st Gear b06x6x Countershaft 4 Out 5 Countershaft

More information

SECTION B Manual Transaxle/Transmission TR6060

SECTION B Manual Transaxle/Transmission TR6060 308-03B-i Manual Transaxle/Transmission TR6060 308-03B-i SECTION 308-03B Manual Transaxle/Transmission TR6060 CONTENTS PAGE Transmission... 308-03B-2 308-03B-2 Manual Transaxle/Transmission TR6060 308-03B-2

More information

MANUAL TRANSAXLE Return to Main Table of Contents

MANUAL TRANSAXLE Return to Main Table of Contents MANUAL TRANSAXLE Return to Main Table of Contents GENERAL... 2 MANUAL TRANSAXLE CONTROL... 12 SHIFT LEVER ASSEMBLY... 14 MANUAL TRANSAXLE... 15 MANUAL TRANSAXLE ASSEMBLY... 17 FIFTH SPEED SYNCHRONIZER

More information

Transmission Overhaul Procedures-Bench Service

Transmission Overhaul Procedures-Bench Service How to Assemble the Lower Reverse Idler Gear Assembly Special Instructions In 1996 Eaton changed the reverse idler system design. In the nut design, the reverse idler bearing was lubricated through a hole

More information

TRANSMISSION 6.7 GENERAL HOME. See Figure The transmission is a five-speed constantmesh type housed in an extension of the crankcase.

TRANSMISSION 6.7 GENERAL HOME. See Figure The transmission is a five-speed constantmesh type housed in an extension of the crankcase. TRANSMISSION 6.7 GENERAL See Figure 6-46. The transmission is a five-speed constantmesh type housed in an extension of the crankcase. b06x6x Neutral st Gear Mainshaft Mainshaft 4 5 4 5 Countershaft Out

More information

MP140 - SERVICE Dodge Nitro R/T TRANSFER CASE MP140 - Service Information - Nitro DESCRIPTION

MP140 - SERVICE Dodge Nitro R/T TRANSFER CASE MP140 - Service Information - Nitro DESCRIPTION 1 - INPUT SEAL 15 - WEAR SLEEVE 2 - VENT 16 - FLANGE 3 - FRONT CASE 17 - FLANGE SEAL 4 - INPUT GEAR 18 - FLANGE NUT 5 - PILOT BEARING 19 - ID. TAG 6 - PLANETARY GEAR 20 - DRAIN/FILL PLUGS 7 - SPROCKET

More information

INSTRUCTIONS. Disassembly. Shifter Cam Assembly. Shifter Forks

INSTRUCTIONS. Disassembly. Shifter Cam Assembly. Shifter Forks INSTRUCTIONS Disassembly To protect against accidental start-up of vehicle, always disconnect the negative battery cable before working on the motorcycle. Failure to disconnect the battery cable could

More information

Maintenance Information

Maintenance Information 80234313 Edition 1 June 2006 Air Grinder, Die Grinder, Sander and Belt Sander Series G1 (Angle) Maintenance Information Save These Instructions WARNING Always wear eye protection when operating or performing

More information

ASSEMBLY. Transmission Automatic Transmission 5R44E and 5R55E. Special Tool(s)

ASSEMBLY. Transmission Automatic Transmission 5R44E and 5R55E. Special Tool(s) 307-01-1 Automatic Transmission 5R44E and 5R55E 307-01-1 ASSEMBLY Transmission Special Tool(s) Holding Fixture, Transmission 307-262 (T93T-77002-AH) Special Tool(s) Installer, Transmission Extension Housing

More information

PL TRANSAXLE 21-1 TRANSAXLE TABLE OF CONTENTS NV T350 (A-578) MANUAL TRANSAXLE TH AUTOMATIC TRANSAXLE NV T350 (A-578) MANUAL TRANSAXLE

PL TRANSAXLE 21-1 TRANSAXLE TABLE OF CONTENTS NV T350 (A-578) MANUAL TRANSAXLE TH AUTOMATIC TRANSAXLE NV T350 (A-578) MANUAL TRANSAXLE PL TRANSAXLE 21-1 TRANSAXLE TABLE OF CONTENTS page page NV T350 (A-578) MANUAL TRANSAXLE... 1 31TH AUTOMATIC TRANSAXLE... 54 NV T350 (A-578) MANUAL TRANSAXLE TABLE OF CONTENTS page GENERAL INFORMATION

More information

1 of 25 9/12/2013 9:07 PM

1 of 25 9/12/2013 9:07 PM 1 of 25 9/12/2013 9:07 PM 46RE Automatic Transmission DISASSEMBLY 1. Clean exterior of transmission with suitable solvent or pressure washer. 2. Place transmission in vertical position. 3. Measure the

More information

TSM54/52 MANUAL TRANSMISSION

TSM54/52 MANUAL TRANSMISSION 3B-1 SECTION 00 3B TSM54/52 MANUAL TRANSMISSION Table of Contents GENERAL INFORMATION... 3B-3 Overview... 3B-3 Specifications... 3B-4 System components... 3B-5 Shifting mechanism... 3B-17 Diagnostic information

More information

Maintenance Information

Maintenance Information 80234313 Edition 2 May 2014 Air Grinder, Die Grinder, Sander and Belt Sander Series G1 (Angle) Maintenance Information Save These Instructions Product Safety Information WARNING Failure to observe the

More information

TRANSFER CASE Mitsubishi Montero APPLICATION DESCRIPTION TESTING 4WD INDICATOR CONTROL UNIT (MONTERO) DETECTION SWITCH

TRANSFER CASE Mitsubishi Montero APPLICATION DESCRIPTION TESTING 4WD INDICATOR CONTROL UNIT (MONTERO) DETECTION SWITCH TRANSFER CASE 1993 Mitsubishi Montero 1991-94 TRANSFER CASES Mitsubishi Dodge; Ram-50 Mitsubishi; Pickup, Montero APPLICATION TRANSFER CASE APPLICATIONS TABLE Application (1) Transmission Model Dodge 1991-93

More information

1984 Dodge W250 PICKUP

1984 Dodge W250 PICKUP 1984 Dodge W250 PICKUP Submodel: Engine Type: V8 Liters: 5.2 Fuel Delivery: CARB Fuel: GAS Dana 44 MODELS THROUGH 1984 2. Raise and safely support the vehicle, then remove the wheel hub and bearings as

More information

MANUAL TRANSMISSION SECTION MT CONTENTS TRANSMISSION/TRANSAXLE MT-1 SERVICE INFORMATION POSITION SWITCH...13 Checking...13

MANUAL TRANSMISSION SECTION MT CONTENTS TRANSMISSION/TRANSAXLE MT-1 SERVICE INFORMATION POSITION SWITCH...13 Checking...13 TRANSMISSION/TRANSAXLE SECTION MT A B MANUAL TRANSMISSION MT D CONTENTS E SERVICE INFORMATION... 2 PRECAUTIONS... 2 Service Notice or Precaution...2 PREPARATION... 3 Special Service Tool...3 Commercial

More information

LoMax 205 CASE & 3:1 GEAR SET. Manufactured by JB CONVERSIONS, INC. Phone: Installation Instructions for the GM NP205 Transfer Case

LoMax 205 CASE & 3:1 GEAR SET. Manufactured by JB CONVERSIONS, INC. Phone: Installation Instructions for the GM NP205 Transfer Case LoMax 205 CASE & 3:1 GEAR SET Part No. 2800 Instruction Rev: 2007.08.16 Manufactured by JB CONVERSIONS, INC. Phone: Installation Instructions for the GM NP205 Transfer Case Kit Components: 1. (1) 42x25

More information

Installation Instructions

Installation Instructions Instructions Created by an: 86-95 Suzuki Samurai Samurai Complete Transmission Rebuild Kit with Synchronizers (SKU# STM-RP) Installation Instructions Part I Notice: If there are any parts you need that

More information

2002 F-Super Duty /Excursion Workshop Manual

2002 F-Super Duty /Excursion Workshop Manual Page 1 of 25 SECTION 307-01: Automatic Transaxle/Transmission 2002 F-Super Duty 250-550/Excursion Workshop Manual ASSEMBLY Procedure revision date: 05/23/2001 Transmission Special Tool(s) Remover, O-Ring

More information

Maintenance Information

Maintenance Information 45528270 Edition 1 June 2007 Barring Motor T480 Series Maintenance Information Save These Instructions WARNING Always wear eye protection when operating or performing maintenance on this Barring Motor.

More information

NV4500 TRANSMISSION SERVICE

NV4500 TRANSMISSION SERVICE 4X4 TECHNICAL MANUAL TM1003 NV4500 TRANSMISSION SERVICE DAN GUARINO 4X4 TECH INC. 4x4 Tech Inc. Roberts, Montana U.S.A. COPYRIGHT 2005-2006 4X4 TECH INC. UNAUTHORIZED REPRODUCTION OR DUPLICATION PROHIBITED

More information

DRIVE AXLE Volvo 960 DESCRIPTION & OPERATION AXLE IDENTIFICATION DRIVE AXLES Volvo Differentials & Axle Shafts

DRIVE AXLE Volvo 960 DESCRIPTION & OPERATION AXLE IDENTIFICATION DRIVE AXLES Volvo Differentials & Axle Shafts DRIVE AXLE 1994 Volvo 960 1994 DRIVE AXLES Volvo Differentials & Axle Shafts 960 DESCRIPTION & OPERATION All 960 station wagon models use type 1041 rear axle assembly. All 960 4-door models use type 1045

More information

MANUAL TRANSMISSIONS Mitsubishi F4M20, F5M20, F5M30 & KM200 Series TRANSMISSION APPLICATION

MANUAL TRANSMISSIONS Mitsubishi F4M20, F5M20, F5M30 & KM200 Series TRANSMISSION APPLICATION Article Text ARTICLE BEGINNING MANUAL TRANSMISSIONS Mitsubishi F4M20, F5M20, F5M30 & KM200 Series APPLICATION TRANSMISSION APPLICATION Vehicle Application Transmission Model Chrysler Motors (2WD) 4-Speed

More information

MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2)

MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2) MANUAL TRANSMISSION 7B 1 RODEO TRANSMISSION MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2) CONTENTS Service Precaution...................... 7B 2 General Description..................... 7B

More information

Reverse Idler Gear Shaft

Reverse Idler Gear Shaft «1993 Thunderbird/Cougar Table of Contents» «Group 07: TRANSMISSION» «Section 07-03: Transmission, Manual--M5R2» «DISASSEMBLY AND ASSEMBLY» Reverse Idler Gear Shaft Disassembly Remove the following parts

More information

Maintenance Information

Maintenance Information 04581245 Edition 2 May 2014 Air Grinder, Die Grinder and Sander Series G2 (Angle) Maintenance Information Save These Instructions Product Safety Information WARNING Failure to observe the following warnings,

More information

DESCRIPTION AND OPERATION. Description

DESCRIPTION AND OPERATION. Description file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk73001.htm~gen~ref.htm Page 1 of 1 Section 07-03: Transmission, Manual, M5OD DESCRIPTION AND OPERATION 1997 Ranger Workshop Manual Description The M5OD

More information

Maintenance Instructions

Maintenance Instructions General Note These instructions contain information common to more than one model of Bevel Gear Drive. To simplify reading, similar models have been grouped as follows: GROUP 1 Models 11, 0, 1,, (illustrated),,

More information

CHAPTER 7 TRANSMISSION (MFO6S)

CHAPTER 7 TRANSMISSION (MFO6S) 1 page INDEX1 Model SG1J (MF06S) TRANSMISSION 7-1 7-142E-07 CHAPTER 7 TRANSMISSION (MFO6S) Model SG1J 1 Models FE, FF and SG2J 1 Model FD 7 TROUBLESHOOTING...7-2 SPECIAL TOOLS...7-5 REMOVAL...7-7 GEAR

More information

Borg & Beck Clutch Information

Borg & Beck Clutch Information Borg & Beck Clutch Information After the clutch is bolted to the flywheel, under no circumstance should the release lever, or the release lever plate if equipped, be pulled away from the flywheel against

More information

CLUTCH CONTENTS SERVICE DIAGNOSIS. (a) Worn or damaged disc assembly. (b) Grease or oil on disc facings. (c) Improperly adjusted cover assembly.

CLUTCH CONTENTS SERVICE DIAGNOSIS. (a) Worn or damaged disc assembly. (b) Grease or oil on disc facings. (c) Improperly adjusted cover assembly. CLUTCH CONTENTS -GROUP 6 Page CLUTCH HOUSING ALIGNMENT... 6 CLUTCH PEDAL FREE PLAY 1 CLUTCH RELEASE BEARING 5 CLUTCH RELEASE FORK... 5 CLUTCH SERVICING 2 PILOT BUSHING CRANKSHAFT TO TRANSMISSION DRIVE

More information

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY 205-03-1 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-1 DISASSEMBLY AND ASSEMBLY Axle Front Drive Special Tool(s) 2-Jaw Puller 205-D072 (D97L-4221-A) Special Tool(s) Carrier Bearing Replacer

More information

Installation Instructions for the Tera low range Dana 20 (LOW20)

Installation Instructions for the Tera low range Dana 20 (LOW20) Installation Instructions for the Tera low range Dana 20 (LOW20) Tera Manufacturing, Inc. 5251 South Commerce Dr. Murray, Utah 84107 Phone/801.288.2585 Fax/801.288.2571 www.teraflex.biz Attention: Verify

More information

MTMANUAL TRANSMISSION GENERAL 1. SPECIFICATIONS. 1) General Specifications. 2) Tightening Torque MANUAL TRANSMISSION

MTMANUAL TRANSMISSION GENERAL 1. SPECIFICATIONS. 1) General Specifications. 2) Tightening Torque MANUAL TRANSMISSION 03-3 MT GENERAL 1. SPECIFICATIONS 1) General Specifications 2) Tightening Torque 03-4 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW 4WD Features 1. All gears use the helical type and high strength materials.

More information

AUTOMATIC TRANSMISSIONS Mitsubishi F3A20 Series TRANSMISSION APPLICATION TABLE

AUTOMATIC TRANSMISSIONS Mitsubishi F3A20 Series TRANSMISSION APPLICATION TABLE Article Text ARTICLE BEGINNING AUTOMATIC TRANSMISSIONS Mitsubishi F3A20 Series APPLICATION TRANSMISSION APPLICATION TABLE Vehicle Application Transmission Model Colt 3-Speed (1990-94)... F3A21 Colt Vista

More information

2001 F-650/750 Workshop Manual

2001 F-650/750 Workshop Manual 26. Pack the reverse idler gear bearings with lubricant. Use Moly number 2 lubricant or equivalent. 27. Install the following: 1. Assemble the reverse idler gear and bearings onto the idler shaft. 2. Position

More information

ASSEMBLY. Transmission Automatic Transaxle/Transmission. Special Tool(s) Alignment Set, Fluid Pump 307-S039 (T74P X) Special Tool(s)

ASSEMBLY. Transmission Automatic Transaxle/Transmission. Special Tool(s) Alignment Set, Fluid Pump 307-S039 (T74P X) Special Tool(s) 307-01-1 Automatic Transaxle/Transmission 307-01-1 ASSEMBLY Transmission Special Tool(s) Adjustment Set, Transmission Band 307-S022 (T71P-77370-A) Special Tool(s) Alignment Set, Fluid Pump 307-S039 (T74P-77103-X)

More information

SUZUKI SQ 416/420/625 M.Y TRANSMISSION SERVICE MANUAL - MANUAL - AUTOMATIC - TRANSFER - DIFFERENTIALS

SUZUKI SQ 416/420/625 M.Y TRANSMISSION SERVICE MANUAL - MANUAL - AUTOMATIC - TRANSFER - DIFFERENTIALS SUZUKI SQ 416/420/625 M.Y 1998-2005 TRANSMISSION SERVICE MANUAL - MANUAL - AUTOMATIC - TRANSFER - DIFFERENTIALS WARNING/CAUTION/NOTE IMPORTANT Please read this manual and follow its instructions carefully.

More information

1994 Mitsubishi Eclipse GS

1994 Mitsubishi Eclipse GS APPLICATIONS CHRYSLER MOTORS MANUAL TRANS OVERHAUL - MITSUBISHI W5M & W6M SERIES MANUAL TRANSMISSIONS Mitsubishi W5M31, TRANSMISSION APPLICATIONS (CHRYSLER MOTORS) Vehicle Application Transmission Model

More information

Technical Service Bulletin

Technical Service Bulletin Page 1 of 41 MITSUBISHI MOTORS Technical Service Bulletin SUBJECT No: NOISE FROM CVT AT ALL ENGINE SPEEDS DATE: February, 2015 MODEL: See below CIRCULATE TO: I[ ]GENERAL MANAGER I [ X l PARTS MANAGER I

More information

MANUAL TRANSMISSION SECTION MT CONTENTS C TRANSMISSION/TRANSAXLE MT-1

MANUAL TRANSMISSION SECTION MT CONTENTS C TRANSMISSION/TRANSAXLE MT-1 MANUAL TRANSMISSION C TRANSMISSION/TRANSAXLE SECTION MT A B MANUAL TRANSMISSION MT D CONTENTS E PRECAUTIONS... 2 Caution... 2 Precautions for Battery Service... 2 PREPARATION... 3 Special Service Tools...

More information

70001 and Clutch Rebuild Instructions

70001 and Clutch Rebuild Instructions 70001 and 70010 Clutch Rebuild Instructions Brinn, Incorporated 1615 Tech Drive Bay City, MI 48706 Telephone 989.686.8920 Fax 989.686.6520 www.brinninc.com Notice Use these instructions if you only want

More information

InstalL Instructions. trail-creeper 4.70 transfer case gear kit ( KIT and KIT) kit contents

InstalL Instructions. trail-creeper 4.70 transfer case gear kit ( KIT and KIT) kit contents InstalL Instructions trail-creeper 4.70 transfer case gear kit (105000-1-KIT and 105001-1-KIT) kit contents 5356 PINE AVE FRESNO, CA 93727 USA TOLL FREE: 877.4X4.TOYS WORLDWIDE: 559.252.4950 WWW.TRAIL-GEAR.COM

More information

REMOVAL TF REMOVE TRANSFER INDICATOR SWITCH (a) Remove the switches and gaskets. HINT: Indicator switch:

REMOVAL TF REMOVE TRANSFER INDICATOR SWITCH (a) Remove the switches and gaskets. HINT: Indicator switch: 20 NO. 1 NO. 2 F043499 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag

More information

1999 F-150/250 Workshop Manual

1999 F-150/250 Workshop Manual Page 1 of 30 SECTION 205-03: Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 1999 F-150/250 Workshop Manual DISASSEMBLY AND ASSEMBLY Procedure revision date: 01/08/2003 Axle Front Drive Special Tool(s)

More information

DRIVE AXLE Nissan 240SX DESCRIPTION & OPERATION AXLE RATIO & IDENTIFICATION AXLE SHAFT & BEARING R & I DRIVE SHAFT R & I

DRIVE AXLE Nissan 240SX DESCRIPTION & OPERATION AXLE RATIO & IDENTIFICATION AXLE SHAFT & BEARING R & I DRIVE SHAFT R & I DRIVE AXLE 1990 Nissan 240SX 1990 DRIVE AXLES Rear Axle - R200 240SX, 300ZX DESCRIPTION & OPERATION The axle assembly is a hypoid type gear with integral carrier housing. The pinion bearing preload adjustment

More information

Valtek Auxiliary Handwheels and Limit Stops

Valtek Auxiliary Handwheels and Limit Stops Valtek Auxiliary s and Limit Stops Table of Contents Page 1 General information 2 Installation 2 Side-mounted handwheels, size 25 and 50 (linear actuators) 3 Side-mounted handwheels, size 100 and 200 (linear

More information

Maintenance Information

Maintenance Information 16575243 Edition 2 October 2013 Air Screwdrivers 1R Series Maintenance Information Save These Instructions Product Safety Information WARNING Failure to observe the following warnings, and to avoid these

More information

1. General Description

1. General Description 1. General Description A: SPECIFICATION 1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL Type Transmission gear ratio Front reduction gear Rear reduction gear Front differential Center differential Final

More information

Model 306B H&J Transfer Case Service Manual

Model 306B H&J Transfer Case Service Manual Model 306B H&J Transfer Case Service Manual For innovation using today s technology in demanding situations call: Phone: (877) 327-2116 Fax: (586) 601-1904 e-mail: info@mixerandplantparts.com Mixer & Plant

More information

2006 Dodge RAM of 10 11/15/ :03 PM REMOVAL. Subarticles. Submodel: SLT Engine Type: V8 Liters: 5.7 Fuel Delivery: FI Fuel: GAS

2006 Dodge RAM of 10 11/15/ :03 PM REMOVAL. Subarticles. Submodel: SLT Engine Type: V8 Liters: 5.7 Fuel Delivery: FI Fuel: GAS EAR-PINION/RING - REMOVAL AND INSTALLATION 1 of 10 11/15/2012 12:03 PM 2006 Dodge RAM 1500 Submodel: SLT Engine Type: V8 Liters: 5.7 Fuel Delivery: FI Fuel: GAS Subarticles GEAR-PINION/RING - REMOVAL GEAR-PINION/RING

More information

3.2 DRIVE TORQUE HUB. Roll, Leak and Brake Testing SECTION 3 - CHASSIS & TURNTABLE. 3-2 JLG Lift

3.2 DRIVE TORQUE HUB. Roll, Leak and Brake Testing SECTION 3 - CHASSIS & TURNTABLE. 3-2 JLG Lift 3.2 DRIVE TORQUE HUB Roll, Leak and Brake Testing 10 LUG PATTERN Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings

More information

MANUAL TRANSMISSION SECTIONMT CONTENTS IDX FS5W71C. Case Components...27

MANUAL TRANSMISSION SECTIONMT CONTENTS IDX FS5W71C. Case Components...27 MANUAL TRANSMISSION SECTIONMT GI MA EM LC EC CONTENTS FE FS5W71C PREPARATION...3 Special Service Tools...3 Commercial Service Tools...5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...6 NVH Troubleshooting

More information

1.28 ACCESSORY DRIVE. Accessory Drive Assembly Related Parts (Former Design) SERIES 60 SERVICE MANUAL. 1. Locknut 8. Drive Gear

1.28 ACCESSORY DRIVE. Accessory Drive Assembly Related Parts (Former Design) SERIES 60 SERVICE MANUAL. 1. Locknut 8. Drive Gear SERIES 60 SERVICE MANUAL 1.28 ACCESSORY DRIVE The accessory drive assembly is mounted to the front of the gear case cover and utilizes a two-groove pulley to drive the alternator. See Figure 1-413, and

More information

GEARBOX AND 4X4 COUPLING UNIT SERVICE TOOLS SERVICE TOOLS OTHER SUPPLIER SERVICE PRODUCTS

GEARBOX AND 4X4 COUPLING UNIT SERVICE TOOLS SERVICE TOOLS OTHER SUPPLIER SERVICE PRODUCTS GEARBOX AND 4X4 COUPLING UNIT SERVICE TOOLS Description Part Number Page BLIND HOLE BEARING PULLER SET... 529 036 117... 199 COUNTERSHAFT OIL SEAL PUSHER... 529 036 222... 192 ECM ADAPTER TOOL... 529 036

More information

Page 1 of 22 SECTION 307-01: Automatic Transaxle/Transmission 4R70E/4R75E ASSEMBLY Procedure revision date: 05/29/2009 Transmission Printable View (1554 KB) Special Tool(s) Air Test Plate, Transmission

More information

MANUAL TRANSMISSION SECTIONMT CONTENTS IDX FS5W71C. ASSEMBLY...24 Gear Components...24

MANUAL TRANSMISSION SECTIONMT CONTENTS IDX FS5W71C. ASSEMBLY...24 Gear Components...24 MANUAL TRANSMISSION SECTIONMT GI MA EM LC EC CONTENTS FE FS5W71C PREPARATION...3 Special Service Tools...3 Commercial Service Tools...5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...6 NVH Troubleshooting

More information

4.2 WATER PUMP (GEAR CASE MOUNTED AND LATER) (GCM)

4.2 WATER PUMP (GEAR CASE MOUNTED AND LATER) (GCM) SERIES 60 SERVICE MANUAL 4.2 WATER PUMP (GEAR CASE MOUNTED - 1991 AND LATER) (GCM) The centrifugal-type water pump circulates the engine coolant through the cooling system. The pump is mounted on the rear

More information

Char-Lynn Hydraulic Motor. Repair Information Series. April, 1997

Char-Lynn Hydraulic Motor. Repair Information Series. April, 1997 Char-Lynn Hydraulic Motor April, 1997 Repair Information Geroler Motors 002 00 004 Parts Drawing 1 See Note 2 Page 1 22 1 9 1-1/4 Split Flange Ports 8 7 6 5 B 1 See Note 2 Page 2 24 4 14 19 20 15 1 18

More information

Maintenance Information

Maintenance Information 16572679 Edition 2 May 2014 Air Drill QP Series Maintenance Information Save These Instructions Product Safety Information WARNING Failure to observe the following warnings, and to avoid these potentially

More information

Zoom and Print Options

Zoom and Print Options 1 of 63 8/26/2017, 7:04 AM Vehicle» Transmission and Drivetrain» Transfer Case» Service and Repair» Procedures» Isuzu T150» Overhaul (Unit Repair)» 1. Transfer Case Disassemble Transfer Case Disassemble

More information

NOTE: Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.

NOTE: Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring. ASSEMBLY (AUTOMATIC 545RFE)... ASSEMBLY NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate

More information

AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE SYSTEM... COMPONENT PARTS...

AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE SYSTEM... COMPONENT PARTS... SYSTEM....... COMPONENT PARTS.................... OIL PUMP.............................. DIRECT CLUTCH........................ FORWARD CLUTCH..................... SECOND BRAKE........................ UNDERDRIVE

More information

SECTION 7B3 - MANUAL TRANSMISSION - GEN III V8 ENGINE

SECTION 7B3 - MANUAL TRANSMISSION - GEN III V8 ENGINE SECTION 7B3 - MANUAL TRANSMISSION - GEN III V8 ENGINE CAUTION: This vehicle will be equipped with a Supplemental Restraint System (SRS). An SRS will consist of either seat belt pre-tensioners and a driver's

More information

15.Main Shaft Assembly

15.Main Shaft Assembly 15.Main Shaft Assembly A: REMOVAL 1) Remove the manual transmission assembly from vehicle. 2) Remove the transfer case with extension case assembly.

More information

MANUAL TRANSAXLE SECTIONMT CONTENTS IDX. Shift Control Components...34

MANUAL TRANSAXLE SECTIONMT CONTENTS IDX. Shift Control Components...34 MANUAL TRANSAXLE SECTIONMT GI MA EM LC EC CONTENTS FE PREPARATION...3 Special Service Tools...3 Commercial Service Tools...5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...6 NVH Troubleshooting

More information

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY 307-01-1 Automatic Transaxle/Transmission 307-01-1 DISASSEMBLY AND ASSEMBLY Transaxle Special Tool(s) Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C) Special Tool(s) Test Plate Screw Set,

More information

Maintenance Information

Maintenance Information 16584062 Edition 3 December 2013 High Torque Reversible Angle Screwdrivers and Angle Wrenches QA1L High Torque Series Maintenance Information Save These Instructions Product Safety Information WARNING

More information

ABBREVIATIONS USED IN THIS

ABBREVIATIONS USED IN THIS IN10 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL ATF Automatic Transmission Fluid B 0 Overdrive Brake B 2 Second Brake B 3 No. 3 Brake C 0 Overdrive Direct Clutch C

More information

1989 Jeep Cherokee. STEERING COLUMN' '1989 STEERING Jeep Steering Columns STEERING COLUMN STEERING Jeep Steering Columns

1989 Jeep Cherokee. STEERING COLUMN' '1989 STEERING Jeep Steering Columns STEERING COLUMN STEERING Jeep Steering Columns STEERING COLUMN 1989 STEERING Jeep Steering Columns DESCRIPTION All models use collapsible steering columns. All columns have integral ignition switch and locking device. Optional tilt wheel is available

More information

1. General Description

1. General Description 1. General Description A: SPECIFICATIONS 1. Type Transmission gear ratio Front reduction gear Rear reduction gear 2. TRANSMISSION GEAR OIL Recommended oil Final Transfer 5-forward speeds with synchromesh

More information

Installation and Parts Replacement Manual For No. 188D BIO-DISC Reducer

Installation and Parts Replacement Manual For No. 188D BIO-DISC Reducer Installation and Parts Replacement Manual For No. 88D BIO-DISC Reducer These instructions must be read thoroughly before installation or operation. This instruction manual was accurate at the time of printing.

More information

Maintenance Information

Maintenance Information Form 16573321 Edition 1 July 2004 Air Grinder Series 61H Maintenance Information Save These Instructions Always wear eye protection when operating or performing maintenance on this tool. Always turn off

More information

STERNDRIVE UNIT 3 B GEAR HOUSINGS MR/ALPHA ONE/ALPHA ONE SS

STERNDRIVE UNIT 3 B GEAR HOUSINGS MR/ALPHA ONE/ALPHA ONE SS STERNDRIVE UNIT 3 B 23146 GEAR HOUSINGS MR/ALPHA ONE/ALPHA ONE SS Table of Contents Page Identification........................... 3B-1 Specifications.......................... 3B-1 Torque Specifications................

More information

Parking Brake Shoe: Adjustments

Parking Brake Shoe: Adjustments 1997 Ford Truck F 350 2WD Pickup V8-460 7.5L VIN G EFI Copyright 2007, ALLDATA 9.50 Page 1 Parking Brake Shoe: Adjustments Transmission-Mounted Parking Brake Disassembly 1. Remove the Parking brake assembly

More information

Transaxle. 1. Mount the transaxle to Bench Mounted Holding Fixture T57L-500-B.

Transaxle. 1. Mount the transaxle to Bench Mounted Holding Fixture T57L-500-B. «1997 Aspire Table of Contents» «Group 07: TRANSAXLE» «Section 07-01: Transaxle, Automatic» «DISASSEMBLY» Transaxle CAUTION: To prevent dirt from entering the transaxle, it should be disassembled and kept

More information

Remanufactured Transmissions, Spare Parts, and Kits Catalog

Remanufactured Transmissions, Spare Parts, and Kits Catalog S6-650 Spare Parts - Gearbox Housing Group 01.010 1319 301 025 Main Housing without Check Valve 005/006/045/046/049/050 1319 301 093 Main Housing without Check Valve 083/085/084/086 1319 301 084 Main Housing

More information

Discount-Equipment.com

Discount-Equipment.com REQUIRED TOOLS LS Series Remix Shaft Installation Instructions /8", /6", /2" Allen Wrenches Snap Ring Pliers (Light Duty) /" Combination Wrench Loctite #22 Blue /" Socket w/ /8" Ratchet Electric Drill

More information

kit (17% High Range Reduction, 87% Low Range Reduction)

kit (17% High Range Reduction, 87% Low Range Reduction) InstalL Instructions suzuki jimny electric/push-button transfer Case gears 304088-3-kit (17% High Range Reduction, 87% Low Range Reduction) kit contents INCLUDED NOTE: If your Jimny has an automatic transmission,

More information

Parts List Single Reduction Models, Cast Iron Units

Parts List Single Reduction Models, Cast Iron Units Parts List Single Reduction Models, Cast Iron Units 60 51 51 10 24 11 11 9 24 12 19 17 27 31 8 23 7 14 20 28 26 5 1 2 6 44 60 50 23 7 6 30 27 30 4 3 30 13 29 14 22 18 27 43 48 50 8 15 16 12 25 9 51 51

More information

MANUAL TRANSMISSION SECTION MT CONTENTS C TRANSMISSION/TRANSAXLE MT-1

MANUAL TRANSMISSION SECTION MT CONTENTS C TRANSMISSION/TRANSAXLE MT-1 MANUAL TRANSMISSION C TRANSMISSION/TRANSAXLE SECTION MT A B MANUAL TRANSMISSION MT D CONTENTS E PRECAUTIONS... 2 Caution... 2 PREPARATION... 3 Special Service Tools... 3 Commercial Service Tools... 5 NOISE,

More information

RAM P/N AH04415R Double Reduction Wheel Drive SERVICE MANUAL

RAM P/N AH04415R Double Reduction Wheel Drive SERVICE MANUAL RAM P/N AH04415R Double Reduction Wheel Drive SERVICE MANUAL Power Wheel Service Manual Model 7 Double Reduction Wheel Drives AUBURN, INDIANA 46706-3499 U.S.A. PHONE: (219) 925-3200 FAX: (219) 925-4725

More information

Instruction Manual For DODGE. Airport Baggage Handling Systems Speed Reducers

Instruction Manual For DODGE. Airport Baggage Handling Systems Speed Reducers Instruction Manual For DODGE Airport Baggage Handling Systems Speed Reducers ABHS TXT109 - TXT115 - TXT125 ABHS TXT209 - TXT215 - TXT225 ABHS TXT309A - TXT315A - TXT325A ABHS TXT409A - TXT415A - TXT425A

More information

1. Remove the parking brake assembly. 2. Remove the 4 bolts holding the yoke flange and drum. Remove the yoke flange and drive.

1. Remove the parking brake assembly. 2. Remove the 4 bolts holding the yoke flange and drum. Remove the yoke flange and drive. Disassembly NOTE: To replace the brake assembly, brake shoe and lining assemblies, or other operational components the complete parking brake assembly must be removed from the vehicle. 1. Remove the parking

More information

351GF-15. Hydrant Coupler INSTALLATION / OPERATION / MAINTENANCE MODEL

351GF-15. Hydrant Coupler INSTALLATION / OPERATION / MAINTENANCE MODEL INSTALLATION / OPERATION / MAINTENANCE MODEL 351GF-15 Hydrant Coupler 351GF-15 Hydrant Coupler This installation/operation/maintenance guide is designed to provide instructions for the installation operation

More information

2003 Dodge Pickup R DRIVE AXLES' 'Axle Shafts - Front - Ram Pickup WD DRIVE AXLES

2003 Dodge Pickup R DRIVE AXLES' 'Axle Shafts - Front - Ram Pickup WD DRIVE AXLES 2002-04 DRIVE AXLES Axle Shafts - Front - Ram Pickup 1500 4WD DESCRIPTION Vehicles equipped with 4WD and C205F front axle assembly use equal length axle shaft system to deliver power from front differential

More information

Maintenance Information

Maintenance Information 16573321 Edition 3 February 2014 Air Grinder Series 61H Maintenance Information Save These Instructions Product Safety Information WARNING Failure to observe the following warnings, and to avoid these

More information

13. CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER

13. CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER 13. CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER COMPONENT LOCATION 13-2 SERVICE INFORMATION 13-3 TROUBLESHOOTING 13-4 CRANKCASE SEPARATION 13-5 CRANKSHAFT 13-7 MAIN JOURNAL BEARING 13-9 CRANKPIN BEARING

More information

2005 Toyota RAV AUTOMATIC TRANSMISSIONS U240E & U241E Overhaul

2005 Toyota RAV AUTOMATIC TRANSMISSIONS U240E & U241E Overhaul 2001-05 AUTOMATIC TRANSMISSIONS U240E & U241E Overhaul APPLICATION CAUTION: Flush oil cooler and oil cooler lines prior to transaxle installation. Oil cooling system contamination may cause premature transaxle

More information