Dodge Dakota (R1). Manual — part 744
COUNTERSHAFT
Inspect the countershaft gear teeth. Replace the
countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.
Check condition of the countershaft front bearing.
Replace the bearing if worn, noisy, or damaged.
GEAR AND SYNCHRONIZER
Install the needle bearings in the first, second,
third and counter fifth gears. Install the gears on the
output shaft. Then check oil clearance between the
gears and shaft with a dial indicator (Fig. 57). Oil
clearance for all three gears is 0.16 mm (0.0063 in.)
maximum.
Fig. 51 REVERSE SHIFT RAIL C-RING
1 - C-RING
2 - REVERSE SHIFT RAIL
Fig. 52 REVERSE SHIFT RAIL
1- REVERSE SHIFT RAIL AND FORK
2 - REVERSE SHIFT RAIL BORE
Fig. 53 REVERSE SHIFT RAIL INTERLOCK PIN
1 - REVERSE SHIFT RAIL
2 - MAGNET
3 - INTERLOCK PIN
4 - REVERSE SHIFT FORK
Fig. 54 OUTPUT SHAFT REAR BEARING SNAP-
RING
1 - OUTPUT SHAFT REAR BEARING SNAP-RING
2 - COUNTERSHAFT REAR BEARING SNAP-RING
21a - 18
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
Check synchronizer ring wear (Fig. 58). Insert each
ring in matching gear. Measure clearance between
each ring and gear with feeler gauge. Clearance
should be 0.06 - 1.6 mm (0.024 - 0.063 in.).
Check shift fork-to-synchronizer hub clearance
with a feeler gauge (Fig. 59). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).
Check the condition of the reverse idler gear bush-
ing (Fig. 60). Replace the gear if the bushing is dam-
aged or worn.
ASSEMBLY
SHIFT MECHANISM AND GEARTRAIN
(1) Lubricate countershaft journal and rear bear-
ing with petroleum jelly or gear lubricant.
(2) Position the mainshaft into the intermediate
plate.
(3) Tap mainshaft assembly rear bearing into the
intermediate plate with a rubber mallet.
(4) Install countershaft thru the countershaft rear
bearing journal of the intermediate plate.
(5) Align and mesh the mainshaft and counter-
shaft gears as much as possible.
Fig. 55 MAINSHAFT
1 - INPUT AND OUTPUT SHAFT GEAR ASSEMBLIES
Fig. 56 Check Output Shaft Tolerances
1 - CLUSTER GEAR JOURNAL
Fig. 57 Check Gear–To–Shaft Oil Clearance
1 - GEAR BEING CHECKED
2 - OUTPUT SHAFT
Fig. 58 Check Synchronizer Ring Wear
1 - FEELER GAUGE
2 - SYNCHRONIZER RING
R1
MANUAL - AX15
21a - 19
MANUAL - AX15 (Continued)
(6) Install countershaft bearing over the counter-
shaft bearing boss and into the intermediate plate.
Be sure to leave the snap-ring groove in the bearing
facing the rear of the unit. It may be necessary to tap
on the bearing with a plastic mallet to fully seat the
bearing into intermediate plate.
(7) Verify mainshaft and countershaft gears are
correctly meshed and rotate properly.
(8) Install snap-ring to hold output shaft rear
bearing into the intermediate plate (Fig. 61).
(9) Install countershaft rear bearing snap-ring.
NOTE: Coat all shift components with petroleum
jelly during assembly. Petroleum jelly will hold com-
ponents in position during installation.
(10) Install interlock pin in reverse shift rail (Fig.
62).
(11) Install reverse shift rail in the intermediate
plate (Fig. 63).
Fig. 59 Check Fork–To–Hub Clearance
1 - SHIFT FORK
2 - FEELER GAUGE
3 - SYNCHRONIZER SLEEVE
Fig. 60 Reverse Idler Gear Bushing
1 - CHECK BUSHING FOR WEAR OR DAMAGE
2 - REVERSE IDLER GEAR
Fig. 61 OUTPUT SHAFT REAR BEARING SNAP-
RING
1 - OUTPUT SHAFT REAR BEARING SNAP-RING
2 - COUNTERSHAFT REAR BEARING SNAP-RING
Fig. 62 REVERSE SHIFT RAIL INTERLOCK PIN
1 - REVERSE SHIFT RAIL
2 - MAGNET
3 - INTERLOCK PIN
4 - REVERSE SHIFT FORK
21a - 20
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
(12) Install c-ring to hold the reverse shift rail into
the intermediate plate.
(13) Install 1-2 and 3-4 shift forks into the syn-
chronizer sleeves (Fig. 64).
(14) Install 1-2 shift rail interlock plug in the
intermediate plate (Fig. 65).
(15) Install interlock pin in 1-2 shift rail (Fig. 66).
Fig. 63 REVERSE SHIFT RAIL
1 - REVERSE SHIFT RAIL AND FORK
2 - REVERSE SHIFT RAIL BORE
Fig. 64 SHIFT FORKS
1 - 3-4 SHIFT FORK
2 - 1-2 SHIFT FORK
Fig. 65 1-2 SHIFT RAIL INTERLOCK PLUG
1 - 1-2 SHIFT RAIL INTERLOCK PLUG
2 - INTERMEDIATE PLATE
3 - MAGNET
Fig. 66 1-2 SHIFT RAIL INTERLOCK PIN
1 - 1-2 SHIFT RAIL INTERLOCK PIN
2 - 1-2 SHIFT RAIL
3 - MAGNET
R1
MANUAL - AX15
21a - 21
MANUAL - AX15 (Continued)
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