Dodge Dakota (R1). Manual — part 591
(8) Remove front reverse idler shaft support bolt
and loosen rear bolt (Fig. 18).
(9) Remove reverse idler shaft support by sliding it
straight out of housing.
(10) Remove rear reverse idler shaft bolt.
(11) Remove reverse idler shaft, idler gear, bearing
and thrust washer (Fig. 19).
GEARTRAIN
(1) Remove output shaft bearing retainer bolts
(Fig. 20). Bolts are rear of shift tower opening.
(2) Grab hold of mainshaft and countershaft and
remove geartrain from rear housing (Fig. 21).
Fig. 18 REVERSE IDLER SHAFT/SUPPORT BOLT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 19 REVERSE IDLER ASSEMBLY
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
Fig. 20 OUTPUT SHAFT BEARING RETAINER
BOLTS
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
AT OPPOSITE SIDE OF CASE)
Fig. 21 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
21 - 8
MANUAL - NV1500
AN
MANUAL - NV1500 (Continued)
GEARTRAIN
(1) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(2) Separate countershaft from mainshaft.
(3) Separate input shaft from output shaft.
COUNTERSHAFT
(1) Remove countershaft front and rear bearing
with Puller 8356.
(2) Remove rear bearing race (in rear housing)
with Bearing Race Remover L-4454. Install new race
with Driver C-4656 and Driver Handle C-4171.
(3) Remove bearing shim cap from front housing
(below input shaft bearing retainer). Remove shim.
Drive race through and out of housing with Driver
C-4656 and Driver Handle C-4171. Install new race
into housing from outside. Do not drive all the
way into position. Tightening the shim cap will
install the race to the proper position. Install
shim and shim cap and torque cap bolts to 28.5 N·m
(21 ft. lbs.).
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different.
Remove synchronizer unit as an assembly to avoid
intermixing parts. Mark each synchro hub and
sleeve for assembly reference.
(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembly, third gear syn-
chro ring and third gear with a shop press and Split-
ter 1130. Position splitter between second and third
gears.
(3) Remove third gear needle bearing (Fig. 22).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft.
(5) Remove two-piece thrust washer (Fig. 23). Note
position of washer locating lugs in shaft notches for
installation reference.
(6) Remove second gear and needle bearing (Fig.
24).
(7) Remove 2nd-3rd gear thrust washer locating
pin.
(8) Remove second gear synchro ring and synchro
cone.
(9) Remove 1-2 synchro hub snap ring.
Fig. 22 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 23 TWO-PIECE THRUST WASH
1 - WASHER (2 HALVES)
2 - PIN RELIEF
3 - PIN
Fig. 24 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
AN
MANUAL - NV1500
21 - 9
MANUAL - NV1500 (Continued)
(10) Remove 1-2 synchro hub and sleeve and first
gear from output shaft with shop press and Splitter
1130 (Fig. 25). Position splitter between first and
reverse gears.
(11) Remove first gear needle bearing (Fig. 26).
(12) Remove output shaft bearing snap ring (Fig.
27).
(13) Remove output shaft bearing from shaft with
shop
press
and
Splitter
1130.
Position
splitter
between bearing and fifth gear.
(14) Remove fifth gear (Fig. 28).
(15) Remove fifth gear needle bearing. Spread
bearing apart just enough to clear shoulder on output
shaft (Fig. 29).
(16) Remove fifth-reverse synchro hub snap ring
(Fig. 30).
Fig. 25 1-2 SYNCHRO HUB AND SLEEVE
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - SPECIAL TOOL
1130
Fig. 26 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 27 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 28 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 29 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
21 - 10
MANUAL - NV1500
AN
MANUAL - NV1500 (Continued)
(17) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 31).
(18) Remove reverse gear and needle bearing (Fig.
32).
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar® degreasing solvent, Gunk, or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry, or wipe them dry
with clean shop towels.
INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball or internal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 33). Replace any fork
exhibiting wear or damage in these areas. Do not
attempt to salvage shift forks.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks or scores. The plunger spring should be
straight
and
not
collapsed
or
distorted.
Minor
scratches or nicks on the plunger can be smoothed
with 320/400 grit emery soaked in oil. Replace the
plunger and spring if in doubt about condition. Check
condition of detent plunger bushings. Replace if dam-
aged.
Inspect the shift shaft, shift shaft bushing and
bearing. The shaft lever and the lever bushing that
fits over the lever. Replace the shaft if bent, cracked,
or severely scored. Minor burrs, nicks or scratches
Fig. 30 FIFTH REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
Fig. 31 FIFTH-REVERSE SYNCHRO HUB AND
SLEEVE
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 32 REVERSE GEAR AND NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
AN
MANUAL - NV1500
21 - 11
MANUAL - NV1500 (Continued)
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