Dodge Dakota (R1). Manual — part 748
BEARING RETAINER
REMOVAL
(1) Remove release bearing and lever from the
transmission.
(2) Remove front bearing retainer bolts from the
transmission case.
(3) Remove front bearing retainer.
(4) Remove front bearing retainer seal with a suit-
able pry tool.
INSTALLATION
(1) Install new front bearing retainer seal with
Handle C-4171 and Installer 8209 (Fig. 102).
(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.
(4) Install front bearing retainer and tighten the
bolts to 17 N·m (12 ft. lbs.).
(5) Install release bearing and lever onto the
transmission.
EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove propeller shaft.
(3) Remove extension housing seal with a slide
hammer and puller (Fig. 103).
INSTALLATION
(1) Clean seal bore of extension housing of any
residual sealer material from original seal.
(2) Install new extension housing seal with Han-
dle C-4171 and Installer 8212 (Fig. 104). The seal is
located 0 ± 0.5 mm (0 ± 0.02 in.) to the face of the
extension housing
(3) Install propeller shaft.
(4) Check and add fluid to transmission as neces-
sary.
(5) Lower vehicle.
INSTALLER MD998805
INSTALLER L-4507
Fig. 102 BEARING RETAINER SEAL
1 - HANDLE
2 - INSTALLER
Fig. 103 EXTENSION HOUSING SEAL
1 - SLIDE HAMMER
2 - PULLER
21a - 34
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
COUNTERSHAFT
DISASSEMBLY
(1) Remove select fit snap-ring holding the coun-
tershaft front bearing onto the countershaft (Fig.
105).
(2) Remove countershaft front bearing with Bear-
ing Splitter P-334, a spacer on center of countershaft
and a shop press.
ASSEMBLY
(1) Remove any nicks or burrs on countershaft hub
with fine emery or crocus cloth.
(2) Position countershaft front bearing on the end
of countershaft, with snap-ring groove in the bearing
is facing forward.
(3) Press bearing onto countershaft with Installer
8109 and a shop press.
(4) Select the thickest snap-ring that will fit into
the snap-ring groove of the countershaft.
I.D.
MARK
SNAP RING THICKNESS MM (IN.)
A
2.00 - 2.05
(0.0787 - 0.0807)
B
2.05 - 2.10
(0.0807 - 0.0827)
C
2.10 - 2.15
(0.0827 - 0.0846)
D
2.15 - 2.20
(0.0846 - 0.0866)
E
2.20 - 2.25
(0.0866 - 0.0886)
(5) Install snap-ring to hold countershaft front
bearing onto countershaft.
INPUT SHAFT
DISASSEMBLY
(1) Verify 3-4 synchronizer is in the neutral posi-
tion.
(2) Separate input shaft from output shaft (Fig.
106).
Fig. 104 EXTENSION HOUSING SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
3 - SEAL
Fig. 105 Countershaft Front Bearing Snap-ring
1 - SELECT FIT RING
2 - COUNTERSHAFT
3 - FRONT BEARING
Fig. 106 SEPARATE INPUT AND OUTPUT SHAFTS
1 - INPUT SHAFT ASSEMBLY
2 - OUTPUT SHAFT AND GEAR ASSEMBLY
R1
MANUAL - AX15
21a - 35
EXTENSION HOUSING SEAL (Continued)
(3) Remove output shaft pilot bearing from the
input shaft or output shaft (Fig. 107).
(4) Remove fourth gear synchronizer ring from the
input shaft (Fig. 108).
(5) Remove select fit snap-ring holding the input
shaft bearing on the input shaft.
(6) Remove bearing from the input shaft with
Bearing Splitter P-334 and a shop press.
ASSEMBLY
(1) Position input shaft bearing onto input shaft
with the snap-ring groove in the bearing facing for-
ward.
(2) Install bearing on input shaft with Driver
6052.
(3) Select the thickest snap-ring that will fit into
the snap-ring groove of the input shaft (Fig. 109).
I.D.
MARK
SNAP RING
THICKNESS
MM (IN.)
A
2.10 - 2.15
(0.0827 - 0.0846)
B
2.15 - 2.20
(0.0846 - 0.0866)
C
2.20 - 2.25
(0.0866 - 0.0886)
D
2.25 - 2.30
(0.0886 - 0.0906)
E
2.30 - 2.35
(0.0906 - 0.0925)
F
2.35 - 2.40
(0.0925 - 0.0945)
G
2.40 - 2.45
(0.0945 - 0.0965)
(4) Lubricate output shaft pilot bearing bore of
input shaft with petroleum jelly.
(5) Install output shaft pilot bearing in input shaft
bore.
(6) Install fourth gear synchronizer ring onto the
input shaft.
(7) Install input shaft to output shaft.
Fig. 107 OUTPUT SHAFT PILOT BEARING
1 - OUTPUT SHAFT PILOT BEARING
2 - INPUT SHAFT ASSEMBLY
Fig. 108 INPUT SHAFT COMPONENTS
1 - BEARING
2 - SYNCHRO RING
3 - INPUT SHAFT
4 - BEARING SNAP RING
Fig. 109 Select Input Shaft Bearing Snap-ring
1 - SELECT-FIT SNAP RING
21a - 36
MANUAL - AX15
R1
INPUT SHAFT (Continued)
OUTPUT SHAFT
DISASSEMBLY
NOTE: Refer to (Fig. 110) for parts identification
during disassembly and assembly of the output
shaft.
(1) Remove input shaft and output shaft pilot
bearing from output shaft (Fig. 111), if necessary.
(2) Measure and note thrust clearance of output
shaft gears (Fig. 112). 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.).
(3) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 113).
Fig. 110 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
16 - THRUST WASHER
17 - FIRST GEAR SPACER
18 - SYNCHRO RING
19 - SNAP RING (SELECTIVE)
20 - INSERT SPRING
21 - INSERT (3)
22 - INSERT SPRING
23 - SYNCHRO RING
24 - NEEDLE BEARING
25 - SECOND GEAR
26 - REVERSE GEAR AND 1-2 SLEEVE
27 - OUTPUT SHAFT (4WD)
28 - INSERT (3)
29 - INSERT SPRING
R1
MANUAL - AX15
21a - 37
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