Dodge Dakota (R1). Manual — part 605
(7) Install rear housing onto geartrain (Fig. 97).
Verify bearing retainer pilot stud is in correct bolt
hole in housing. Also be sure countershaft and output
shaft bearings are aligned in housing and on counter-
shaft. It may be necessary to lift upward on counter-
shaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
Fig. 94 REAR HOUSING DOWELS
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
Fig. 95 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY
Fig. 96 COUNTERSHAFT REAR BEARING SEATED
1 - SHIFT SHAFT BUSHING/BEARING
2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE)
Fig. 97 REAR HOUSING - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
21 - 64
MANUAL - NV3500
AN
MANUAL - NV3500 (Continued)
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
(9) Apply Mopar Gasket Maker or equivalent, to
housing bolt threads, bolt shanks and under bolt
heads (Fig. 98).
(10) Start first two bolts in retainer (Fig. 99). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 99).
(12) Tighten all three retainer bolts to 30-35 N·m
(22-26 ft. lbs.).
ADAPTER HOUSING - 4WD
(1) Install rear bearing in adapter housing. Use
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 100).
(3) Apply Mopar Gasket Maker or equivalent, to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 98).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 96).
CAUTION: Be sure the large diameter side of the
roller retainer faces the countershaft and the small
diameter side faces the race and housing (Fig. 96).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 96).
(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 101).
(10) Lubricate lip of new rear seal (Fig. 102) with
Mopar Door Ease or transmission fluid.
Fig. 98 SEAL RETAING BOLTS
1 - MOPAR GASKET MAKER (OR LOCTITE 518)
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 99 PILOT STUD AND RETAINER BOLTS - 2WD
1 - BEARING RETAINER BOLT
2 - ALIGNMENT PIN
Fig. 100 ADAPTER HOUSING - 4WD
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
AN
MANUAL - NV3500
21 - 65
MANUAL - NV3500 (Continued)
(11) Install new rear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 102).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify that all synchro sleeves are in Neutral
position (centered on hub).
CAUTION: The transmission synchros must all be
in Neutral position for assembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
(2) Install 3-4 shift fork in synchro sleeve (Fig.
103). Verify that groove in fork arm is aligned with
grooves in 1-2 and fifth-reverse fork arms as shown.
(3) Slide the end of shift shaft with shaft detent
notches through 3-4 shift fork.
(4) Assemble shift shaft shift lever and bushing
(Fig. 104). Be sure slot in bushing is facing up and
roll pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 105).
(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
106).
Fig. 101 REAR BEARING SNAP RING - 4WD
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 102 REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
Fig. 103 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 104 LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
21 - 66
MANUAL - NV3500
AN
MANUAL - NV3500 (Continued)
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 107).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Positioning of the shift shaft detent
notch is important. Both of the shaft roll pins can
be installed even when the shaft is 180° off. If this
occurs, the transmission will have to be disassem-
bled again to correct shaft alignment.
(9) Select correct new roll pin for shift shaft lever
(Fig. 108). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 109).
(11) Seat shaft lever roll pin with pin punch (Fig.
110).
CAUTION: The shaft lever roll pin must be flush
with the surface of the lever. The lever bushing will
bind on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 110).
(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 111).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket (Fig. 112).
(15) Verify that notches in shift fork arms are
aligned. Realign arms if necessary.
Fig. 105 LEVER AND BUSHING ASSENBLY
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 106 SHAFT IN LEVER OPENING
1 - SHIFT SHAFT
Fig. 107 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 108 ROLL PIN IDENTIFICATION
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
AN
MANUAL - NV3500
21 - 67
MANUAL - NV3500 (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст