Dodge Dakota (R1). Manual — part 749
(4) With Bearing Splitter P-334 positioned under
first gear, press fifth gear, rear bearing, first gear,
and first gear thrust washer off output shaft (Fig.
114).
Fig. 111 OUTPUT SHAFT PILOT BEARING
1 - OUTPUT SHAFT PILOT BEARING
2 - INPUT SHAFT ASSEMBLY
Fig. 112 OUTPUT SHAFT GEAR THRUST
CLEARANCE
1 - THRUST WASHER
2 - FIRST GEAR
3 - REVERSE GEAR AND HUB
4 - SECOND GEAR
5 - THIRD GEAR
6 - 3–4 SYNCHRO SLEEVE AND HUB
7 - OUTPUT SHAFT FLANGE
Fig. 113 FIFTH GEAR SNAP-RING
1 - SNAP RING
Fig. 114 FIFTH GEAR, FIRST GEAR BEARING AND
THRUST WASHER
1 - PRESS RAM
2 - OUTPUT SHAFT
3 - FIRST-FIFTH GEAR-BEARING ASSEMBLY
21a - 38
MANUAL - AX15
R1
OUTPUT SHAFT (Continued)
(5) Remove first gear thrust washer locating pin
from output shaft.
(6) Remove first gear needle roller bearing from
output shaft.
(7) Remove first gear spacer from output shaft.
(8) Remove first gear synchronizer ring.
(9) Remove select fit snap-ring holding the 1-2 syn-
chronizer/reverse gear onto the output shaft.
(10) With Bearing Splitter P-334 positioned under
second gear, press 1-2 synchronizer/reverse gear and
second gear from output shaft (Fig. 115).
(11) Remove second gear needle roller bearing
from the output shaft or second gear.
(12) Remove select fit snap-ring holding the 3-4
synchronizer onto the output shaft (Fig. 116).
(13) Using Bearing Splitter P-334 or suitable press
plates positioned under third gear, press the 3–4 syn-
chronizer and third gear from output shaft (Fig. 117).
(14) Remove third gear needle roller bearing from
output shaft or gear.
Fig. 115 SECOND GEAR, REVERSE GEAR AND 1-2
SYNCHRONIZER/REVERSE GEAR
1 - PRESS RAM
2 - SECOND GEAR
3 - 1-2 SYNCHRONIZER HUB
Fig. 116 3-4 SYNCHRONIZER SNAP RING
1 - 3-4 SYNCHRONIZER SNAP RING
Fig. 117 3-4 SYNCHRONIZER AND THIRD GEAR
1 - 3-4 SYNCHRONIZER
2 - THIRD GEAR
R1
MANUAL - AX15
21a - 39
OUTPUT SHAFT (Continued)
ASSEMBLY
(1) Lubricate transmission components with speci-
fied gear lubricant during assembly.
(2) If necessary, assemble 1-2 and 3-4 synchronizer
hubs, sleeves, springs and key inserts (Fig. 118).
(3) Install third gear needle bearing onto the out-
put shaft.
(4) Install third gear over bearing and onto output
shaft flange.
(5) Install third gear synchronizer ring to third
gear.
(6) Position the 3-4 synchronizer onto the output
shaft.
(7) With Adapter 6761 and a shop press, press the
3-4 synchronizer onto the output shaft.
(8) Select thickest snap-ring that will fit into the
snap-ring groove of the output shaft (Fig. 119).
(9) Install snap-ring to hold 3-4 synchronizer onto
output shaft.
(10) Verify third gear thrust clearance with feeler
gauge (Fig. 120). Clearance should be 0.10-0.30 mm
(0.003-0.0118 in.). If clearance is out of specification,
refer to Cleaning and Inspection section within this
group.
(11) Install second gear needle bearing onto output
shaft.
(12) Install second gear over bearing and onto out-
put shaft flange.
(13) Install second gear synchronizer ring onto sec-
ond gear.
Fig. 118 SYNCHRONIZER IDENTIFICATION
1 - 3-4 SLEEVE AND HUB
2 - REVERSE GEAR AND 1-2 SLEEVE AND HUB
Fig. 119 SELECT 3-4 SYNCHRONIZER SNAP-RIN
I.D. MARK
SNAP RING
THICKNESS
MM (IN.)
A
1.80 - 1.85
(0.0709 - 0.0728)
B
1.85 - 1.90
(0.0728 - 0.0748)
C
1.90 - 1.95
(0.0748 - 0.0768)
D
1.95 - 2.00
(0.0768 - 0.0787)
E
2.00 - 2.05
(0.0787 - 0.0807)
F
2.05 - 2.10
(0.0807 - 0.0827)
G
2.10 - 2.15
(0.0827 - 0.0846)
Fig. 120 THIRD GEAR CLEARANCE
1 - FEELER GAUGE
2 - THIRD GEAR
21a - 40
MANUAL - AX15
R1
OUTPUT SHAFT (Continued)
(14) Position 1-2 synchronizer/reverse gear assem-
bly onto splines of output shaft.
(15) With Installer MD-998805, Adapter 6761, and
a shop press, press the 1-2 synchronizer/reverse gear
onto the output shaft.
(16) Select thickest snap-ring that will fit into the
snap-ring groove of the output shaft (Fig. 121).
I.D.
MARK
SNAP RING
THICKNESS
MM (IN.)
B
2.35 - 2.40
(0.0925 - 0.0945)
C
2.40 - 2.45
(0.0945 - 0.0965)
D
2.45 - 2.50
(0.0965 - 0.0984)
E
2.50 - 2.55
(0.0984 - 0.1004)
F
2.55 - 2.60
(0.1004 - 0.1024)
G
2.60 - 2.65
(0.1024 - 0.1043)
(17) Install snap-ring to hold 1-2 synchronizer/re-
verse gear onto output shaft.
(18) Install first gear synchronizer ring into 1-2
synchronizer/reverse gear.
(19) Install first gear spacer onto the input shaft
and against the 1-2 synchronizer/reverse gear snap-
ring.
(20) Install first gear needle bearing onto output
shaft (Fig. 122).
(21) Install first gear onto output shaft and over
bearing.
(22) Install first gear thrust washer locating pin
into the output shaft.
(23) Install first gear thrust washer onto the out-
put shaft. Rotate thrust washer until the washer
locating pin aligns with the notch in the washer.
(24) Position output shaft rear bearing onto output
shaft with snap ring groove in bearing outer race
toward rear of output shaft.
(25) Install
bearing
onto
output
shaft
with
Installer L-4507 and hammer.
(26) Install snap-ring onto output shaft rear bear-
ing outer race.
Fig. 121 SECOND GEAR AND SYNCHRONIZER
ASSEMBLY
1 - SECOND GEAR
2 - REVERSE GEAR AND 1-2 SLEEVE
3 - FIRST/REVERSE HUB
4 - SELECT FIT SNAP RING
5 - INSERTS AND SPRINGS
6 - SYNCHRO RING
7 - NEEDLE BEARING
Fig. 122 FIRST AND FIFTH GEAR COMPONENTS
1 - SYNCHRO RING
2 - SPACER
3 - PIN
4 - BEARING
5 - FIFTH GEAR
6 - THRUST WASHER
7 - NEEDLE BEARING
8 - FIRST GEAR
R1
MANUAL - AX15
21a - 41
OUTPUT SHAFT (Continued)
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