Dodge Dakota (R1). Manual — part 742
(2) Measure thrust clearance between countershaft
fifth gear and thrust ring with feeler gauge. Clear-
ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).
If clearance exceeds limits the gear/ring will have to
be replaced.
(3) Remove countershaft fifth gear retaining snap-
ring (Fig. 26).
(4) Remove bolt holding fifth gear shift fork to
shift rail (Fig. 27).
Fig. 25 Positioning Intermediate Plate In Vise
1 - VISE JAWS
2 - BOLTS AND WASHERS
3 - INTERMEDIATE PLATE
Fig. 26 FIFTH GEAR SNAP-RING
1 - SNAP-RING
Fig. 27 FIFTH GEAR SHIFT FORK RETANER BOLTS
1 - SHIFT FORK SET SCREW
2 - FIFTH GEAR SHIFT RAIL
3 - FIFTH GEAR SHIFT FORK
21a - 10
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
(5) Move fifth gear shift rail forward until the rail
is clear of the shift fork.
(6) Remove fifth gear shift fork from the synchro-
nizer sleeve (Fig. 28).
(7) Remove reverse shift head and rail assembly
from the intermediate plate (Fig. 29).
(8) Remove fifth gear blocker ring from counter-
shaft assembly with Puller L-4407 (Fig. 30).
(9) Remove fifth gear synchro ring (Fig. 31).
Fig. 28 FIFTH GEAR SHIFT FORK
1 - SHIFT FORK
Fig. 29 REVERSE SHIFT HEAD AND RAIL
ASSEMBLY
1 - HEAD AND RAIL ASSEMBLY
Fig. 30 FIFTH GEAR BLOCKER RING
1 - FIFTH GEAR BLOCKER RING
Fig. 31 FIFTH GEAR SYNCHRO RING
1 - RING
R1
MANUAL - AX15
21a - 11
MANUAL - AX15 (Continued)
(10) Remove fifth gear assembly from countershaft
(Fig. 32).
(11) Remove fifth gear thrust ring from counter-
shaft (Fig. 33).
(12) Remove fifth gear thrust ring lock ball from
countershaft (Fig. 34).
CAUTION: There are many lock balls, check balls,
interlock balls and interlock pins used in various
places in the transmission. Whenever these are
removed they must be identified so they are rein-
stalled in the same location.
(13) Remove bolts holding output shaft rear bear-
ing retainer to intermediate plate (Fig. 35).
Fig. 32 FIFTH GEAR AND SYNCHRO ASSEMBLY
1 - FIFTH GEAR
2 - SYNCHRO
Fig. 33 FIFTH GEAR THRUST RING
1 - LOCK BALL NOTCH
2 - THRUST RING
Fig. 34 FIFTH GEAR THRUST RING LOCK BALL
1 - MAGNET
2 - CLUSTER GEAR
3 - LOCK BALL RECESS
4 - LOCK BALL
Fig. 35 OUTPUT SHAFT REAR BEARING RETAING
BOLTS
1 - BEARING RETAINER
2 - BEARING RETAINER BOLTS
3 - SOCKET AND EXTENSION
21a - 12
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
(14) Remove rear bearing retainer (Fig. 36).
(15) Remove reverse idler gear shaft and gear (Fig.
37).
(16) Remove
bolts
holding
reverse
shift
arm
bracket to intermediate plate (Fig. 38).
(17) Remove threaded lock ball plugs from inter-
mediate plate (Fig. 39).
Fig. 36 OUTPUT SHAFT REAR BEARING RETAINER
1 - OUTPUT SHAFT REAR BEARING RETAINER
Fig. 37 REVERSE IDLER SHAFT AND GEAR
1 - GEAR
2 - SHAFT
Fig. 38 REVERSE SHIFT ARM COMPONENTS
1 - SHIFT ARM BRACKET
2 - REVERSE SHIFT ARM
3 - REVERSE FORK
4 - E-CLIP
Fig. 39 DETENT BALL PLUG LOCATIONS
1 - DETENT BALL PLUGS
2 - INTERMEDIATE PLATE
R1
MANUAL - AX15
21a - 13
MANUAL - AX15 (Continued)
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