Jeep XJ. Manual — part 381
REVERSE IDLER DISASSEMBLY
(1) Remove idler gear snap rings (Fig. 57).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
ASSEMBLY
Gaskets are not used in the NV3550 transmission.
Sealers are used at all case joints. Recommended
sealers are Mopar
t Gasket Maker for all case joints
and Mopar
t silicone sealer, or equivalent, for the
input shaft bearing retainer. Apply these products as
indicated in the assembly procedures.
NOTE: It is very important that the transmission
shift components be in Neutral position during
assembly. This is necessary to prevent damaging
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 (0.0019 in.) thickness incre-
ments. Use the thickest snap ring that will fit in
each snap ring groove.
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.
58).
Fig. 57 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 LOCK BALLS
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NV3550 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
OUTPUT SHAFT
(1) Lubricate shaft, gears and bearings with rec-
ommended 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.
(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 bear-
ing on shaft (Fig. 59). Slide bearing up against shoul-
der on output shaft.
(5) Install reverse gear over needle bearing (Fig.
60).
(6) Install solid brass synchro ring on reverse gear
(Fig. 61).
Fig. 58 Assembled View Of Synchro Components
1 – SLEEVE
2 – HUB SHOULDER
3 – SPRING (3)
4 – STRUT (3)
5 – DETENT BALL (3)
6 – HUB
Fig. 59 Reverse Gear Bearing Installation
1 – REVERSE GEAR BEARING
2 – SHOULDER
Fig. 60 Reverse Gear Installation
1 – REVERSE GEAR
Fig. 61 Reverse Gear Synchro Ring Installation
1 – REVERSE GEAR
2 – SYNCHRO RING (SOLID BRASS)
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NV3550 MANUAL TRANSMISSION
21 - 61
DISASSEMBLY AND ASSEMBLY (Continued)
(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 hub has shoulders
around the hub bore. Make sure this side of the hub
is facing the front of the shaft. In addition, one side
of the sleeve is tapered. Be sure the sleeve is
installed so the tapered side will be facing the front
of the shaft.
(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. 62).
(9) Install new fifth-reverse hub snap ring (Fig.
63) as follows:
(a) Snap rings are available in thicknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 in.).
(b) Install thickest snap ring that will fit in
shaft groove.
(c) Verify that snap ring is completely seated in
groove before proceeding.
(10) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 64).
(11) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 65). Be
sure bearing is properly seated after installation.
(12) Install fifth gear on shaft and onto bearing
(Fig. 66).
Fig. 62 Fifth-Reverse Synchro Assembly Installation
1 – SPACER
2 – PRESS RAM
3 – REVERSE GEAR
4 – FIFTH-REVERSE SYNCHRO ASSEMBLY
5 – SPECIAL TOOL
6310–1
6 – PRESS BLOCKS
7 – OUTPUT SHAFT
Fig. 63 Installing Fifth-Reverse Synchro Hub Snap
Ring
1 – FIFTH-REVERSE SYNCHRO ASSEMBLY
2 – SNAP RING
3 – PRESS BED
4 – PRESS BLOCKS
Fig. 64 Installing Fifth Gear Synchro Ring
1 – FIFTH-SPEED SYNCHRO RING
2 – FIFTH-REVERSE SYNCHRO ASSEMBLY
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NV3550 MANUAL TRANSMISSION
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DISASSEMBLY AND ASSEMBLY (Continued)
(13) Invert output shaft and set the shaft in
Remover 6310-1 so that fifth gear is seated on the
tool (Fig. 67).
(14) Install first gear bearing on output shaft (Fig.
67). Be sure bearing is seated on shaft shoulder and
is properly joined.
(15) Install first gear on shaft and over bearing
(Fig. 68). Make sure bearing synchro cone is facing
up as shown.
Fig. 65 Installing Fifth Gear Bearing
1 – SHAFT SHOULDER
2 – FIFTH GEAR BEARING
Fig. 66 Fifth Gear Installation
1 – FIFTH GEAR
2 – BEARING
Fig. 67 First Gear Bearing Installation
1 – FIRST GEAR BEARING
2 – SHAFT SHOULDER
3 – SPECIAL TOOL
6310–1
4 – PRESS BLOCKS
Fig. 68 First Gear Installation
1 – FIRST GEAR
2 – SPECIAL TOOL
6310–1
3 – BEARING
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NV3550 MANUAL TRANSMISSION
21 - 63
DISASSEMBLY AND ASSEMBLY (Continued)
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