Dodge Dakota (R1). Manual — part 745
(16) Install 1-2 shift rail through intermediate
plate and 1-2 shift fork (Fig. 67).
(17) Install 3-4 shift rail interlock plug into the
intermediate plate (Fig. 68).
(18) Install 3-4 shift rail through the intermediate
plate, 1-2 and 3-4 shift forks (Fig. 69).
(19) Install new bolts to hold the shift forks to the
shift rails (Fig. 70).
Fig. 67 1-2 SHIFT RAIL
1 - INTERMEDIATE PLATE
2 - 1-2 FORK
3 - SHIFT RAIL
Fig. 68 3-4 SHIFT RAIL INTERLOCK PLUG
1 - INTERLOCK PLUG
2 - MAGNET
Fig. 69 3-4 SHIFT RAIL
1 - SHIFT RAIL
Fig. 70 SHIFT FORK TO SHIFT RAIL BOLTS
1 - SHIFT FORK BOLTS
21a - 22
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
(20) Install c-rings to 1-2 and 3-4 shift rails (Fig.
71).
(21) Install fifth gear shift rail lock ball in the
intermediate plate (Fig. 72).
(22) Install fifth gear shift rail into the intermedi-
ate plate.
(23) Install reverse idler gear and idler gear shaft
(Fig. 73). Verify notch in idler shaft is to the rear of
the transmission.
(24) Position output shaft rear bearing retainer on
intermediate plate and into reverse idler shaft notch.
(25) Install new bolts to hold retainer to interme-
diate plate (Fig. 74).
Fig. 71 Shift Rail C-rings
1 - C-RINGS
2 - 3-4 RAIL
3 - 1-2 RAIL
Fig. 72 FIFTH GEAR SHIFT RAIL LOCK BALL
1 - REVERSE SHIFT FORK
2 - MAGNET
3 - LOCK BALL
Fig. 73 REVERSE IDLER SHAFT AND GEAR
1 - GEAR
2 - SHAFT
Fig. 74 Output Shaft Rear Bearing Retainer
1 - REAR BEARING RETAINER TAB
2 - REVERSE IDLER SHAFT NOTCH
R1
MANUAL - AX15
21a - 23
MANUAL - AX15 (Continued)
(26) Install fifth gear thrust ring lock ball into the
countershaft (Fig. 75).
(27) Install fifth gear thrust ring onto countershaft
and over lock ball (Fig. 76).
(28) Install countershaft fifth gear bearing halves
into countershaft fifth gear assembly (Fig. 77).
(29) Install countershaft fifth gear assembly onto
countershaft (Fig. 78).
CAUTION: The fifth gear synchronizer must be
installed on countershaft, with the step on the outer
edge of the synchronizer sleeve towards fifth gear.
Fig. 75 FIFTH GEAR THRUST RING LOCK BALL
1 - MAGNET
2 - CLUSTER GEAR
3 - LOCK BALL RECESS
4 - LOCK BALL
Fig. 76 FIFTH GEAR THRUST RING
1 - LOCK BALL NOTCH
2 - THRUST RING
Fig. 77 Countershaft Fifth Gear Bearings
1 - TWO-PIECE BEARING
2 - FIFTH GEAR AND SYNCHRO ASSEMBLY
Fig. 78 FIFTH GEAR AND SYNCHRO ASSEMBLY
1 - FIFTH GEAR
2 - SYNCHRO
21a - 24
MANUAL - AX15
R1
MANUAL - AX15 (Continued)
(30) Install fifth gear synchro blocker ring (Fig.
79).
(31) Position fifth gear blocker ring onto counter-
shaft. Verify blocker ring and countershaft splines
are aligned.
(32) Seat blocker ring onto the countershaft with
suitable driver and mallet.
(33) Select thickest snap-ring the will fit into the
snap-ring groove of the countershaft.
I.D.
MARK
SNAP RING
THICKNESS
MM (IN.)
A
2.85 - 2.90
(0.1122 - 0.1142)
B
2.90 - 2.95
(0.1142 - 0.1161)
C
2.95 - 3.00
(0.1161 - 0.1181)
D
3.00 - 3.05
(0.1181 - 0.1201)
E
3.05 - 3.10
(0.1201 - 0.1220)
F
3.10 - 3.15
(0.1220 - 0.1240)
G
3.15 - 3.20
(0.1240 - 0.1260)
H
3.20 - 3.25
(0.1260 - 0.1280)
(34) Install snap-ring to hold the countershaft fifth
gear assembly onto the countershaft (Fig. 80).
(35) Install reverse shift head and rail assembly
(Fig. 81).
Fig. 79 FIFTH GEAR SYNCHRO BLOCKER RING
1 - RING
Fig. 80 FIFTH GEAR SNAP-RING
1 - SNAP-RING
Fig. 81 REVERSE SHIFT HEAD AND RAIL
ASSEMBLY
1 - HEAD AND RAIL ASSEMBLY
R1
MANUAL - AX15
21a - 25
MANUAL - AX15 (Continued)
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