Dodge Dakota (R1). Manual — part 600
REAR ADAPTER HOUSING - 4WD
(1) Locate rear seal dimples (Fig. 31). With slide
hammer mounted screw, remove rear seal by insert-
ing screw into one of the seal dimples (Fig. 32).
(2) Remove rear bearing snap ring from output
shaft with snap ring pliers (Fig. 33).
(3) Lift rear adapter housing upward and off
geartrain (Fig. 34).
(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 35). If needed
push or tap bearing out of the housing with a ham-
mer.
(5) Examine condition of bearing bore, counter-
shaft rear bearing race and idler shaft notch in rear
housing. Replace housing if race, bore or notch are
worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove
reverse
idler
gear
assembly
from
assembly fixture cup.
(2) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(3) Slide countershaft out of fixture tool.
Fig. 29 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 30 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - OUTPUT SHAFT
3 - COUNTER SHAFT
Fig. 31 DIMPLES IN SEAL FACE - 4WD
1 - LOCATION OF DIMPLES
2 - SEAL FACE
Fig. 32 REAR SEAL - 4WD
1 - SLIDE HAMMER
2 - REMOVER TOOL
3 - REAR SEAL
21 - 44
MANUAL - NV3500
AN
MANUAL - NV3500 (Continued)
(4) Remove output shaft bearing retainer from
rear surface of fifth gear (retainer will drop onto gear
after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from assembly fixture tool.
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. Remove each
synchronizer unit as an assembly to avoid intermix-
ing parts. Reference mark or tag each synchro hub
and sleeve for correct assembly.
(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 shop press and Bearing
Splitter 1130. Position splitter between second and
third gears.
(3) Remove third gear needle bearing (Fig. 36).
Fig. 33 REAR BEARING SNAP RING - 4WD
1 - HEAVY DUTY SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 34 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
Fig. 35 REAR ADAPTER HOUSING COMPONENTS
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 36 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
AN
MANUAL - NV3500
21 - 45
MANUAL - NV3500 (Continued)
(4) Remove retaining ring that secures two-piece
thrust washer on shaft (Fig. 37). Use a small pry tool
to remove retaining ring.
(5) Remove two-piece thrust washer (Fig. 38). Note
position of washer locating lugs in shaft notches for
installation reference.
(6) Remove second gear and needle bearing (Fig.
39).
(7) Remove second gear synchro ring, synchro fric-
tion cone and synchro cone (Fig. 40).
(8) Remove interm ring.
(9) Remove 1-2 synchro hub snap ring.
Fig. 37 THRUST WASHER
1 - PRY TOOL
2 - THRUST WASHER RETAINING RING
Fig. 38 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2–PIECE)
3 - WASHER LOCATING LUG
Fig. 39 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 40 SECOND GEAR SYNCHRO RING AND
CONES
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
21 - 46
MANUAL - NV3500
AN
MANUAL - NV3500 (Continued)
(10) Remove 1-2 synchro hub and sleeve and first
gear from output shaft with press and Bearing Split-
ter 1130 (Fig. 41). Position splitter between first and
reverse gears.
(11) Remove first gear needle bearing (Fig. 42).
(12) Remove output shaft bearing snap ring (Fig.
43).
(13) On 2-wheel drive models, remove output shaft
bearing.
(14) Remove fifth gear (Fig. 44).
(15) Remove fifth gear needle bearing. Spread
bearing apart just enough to clear shoulder on output
shaft (Fig. 45).
Fig. 41 HUB SLEEVE AND 1-2 SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - SPECIAL TOOL
1130
Fig. 42 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 43 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 44 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 45 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO
CLEAR SHOULDER ON SHAFT)
AN
MANUAL - NV3500
21 - 47
MANUAL - NV3500 (Continued)
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