Dodge Dakota (R1). Manual — part 606
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) Install reverse blocker, retainter and retainer
bolt in front housing.
(2) If previously removed, input shaft bearing in
front housing (Fig. 113). Install snap ring and use
plastic mallet to seat bearing. Bearing goes in from
front side of housing only.
(3) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 113). Large diameter side of
bearing cage goes toward countershaft (Fig. 114).
Small diameter side goes toward bearing race in
housing.
(4) Reach into countershaft front bearing with fin-
ger, and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place. This avoids having rollers becoming dis-
placed during housing installation.
Fig. 109 ROLL PIN IN SHIFT SHAFT
1 - SHAFT LEVER ROLL PIN (” LONG)
2 - LEVER AND BUSHING
Fig. 110 SHIFT SHAFT LEVER ROLL
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 111 ROLL PIN IN SHIFT SOCKET
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 112 SEATING SHIFT SOCKET ROLL PIN
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
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MANUAL - NV3500
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MANUAL - NV3500 (Continued)
(5) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
(6) Apply 1/8 in. wide bead of Mopar Gasket
Maker or equivalent, to mating surfaces of front and
rear housings (Fig. 115).
(7) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(8) Work front housing downward onto geartrain
until seated on rear housing.
CAUTION: If the front housing will not seat on the
rear housing, either the shift components are not in
Neutral, or one or more components are mis-
aligned. Do not force the front housing into place.
This will only result in damaged components.
(9) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(10) Place transmission in horizontal position.
(11) Apply Mopar Gasket Maker or equivalent to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 116).
(12) Install and start housing attaching bolts by
hand (Fig. 116). Then tighten bolts to 34 N·m (25 ft.
lbs.).
(13) Install shift shaft bushing lock bolt (Fig. 117).
Apply Mopar Gasket Maker or equivalent, to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral or the shaft bushing (or
lever) is misaligned.
Fig. 113 INPUT SHAFT AND COUNTERSHAFT
FRONT BEARING
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 115 SEAL FRONT/REAR HOUSINGS
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER
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MANUAL - NV3500
21 - 69
MANUAL - NV3500 (Continued)
(14) Lubricate
then
install
shift
shaft
detent
plunger in housing bore (Fig. 118). Lubricate plunger
with
petroleum
jelly
or
gear
lubricant.
Verify
plunger is fully seated in detent notch in shift
shaft.
(15) Install detent spring inside plunger (Fig. 118).
(16) Install plug on detent spring and compress
spring. Then drive detent plug into transmission case
until plug seats.
(17) Install backup light switch (Fig. 119).
(18) Install input shaft snap ring (Fig. 120).
Fig. 116 HOUSING BOLTS
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
Fig. 117 SHIFT SHAFT BUSHING LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 118 SHIFT SHAFT DETENT PLUNGER
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
Fig. 119 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 120 SHAFT SNAP RING - TYPICAL
1 - INPUT SHAFT SNAP RING
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MANUAL - NV3500
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MANUAL - NV3500 (Continued)
(19) Install new oil seal in front bearing retainer
with Installer 6448 (Fig. 121).
(20) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
122).
(21) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
123). Although retainer is one-way fit on housing, be
sure bolt holes are aligned before seating retainer.
NOTE: Ensure no sealer gets into the oil feed hole
in the transmission case or bearing retainer.
(22) Install and tighten bearing retainer bolts to
7-10 N·m (5-7 ft. lbs.) (Fig. 124).
SHIFT TOWER AND LEVER
(1) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(2) Shift the transmission into third gear.
(3) Align and install shift tower and lever assem-
bly (Fig. 125). Be sure shift ball is seated in socket
and the offset in the tower is toward the passenger
side of the vehicle before installing tower bolts.
(4) Install shift tower bolts (Fig. 126). Tighten
bolts to 8.5 N·m (75.2 in. lbs.).
Fig. 121 OIL SEAL IN FRONT BEARING RETAINER
1 - INSTALLER
2 - FRONT BEARING RETAINER
Fig. 122 SEAL BEARING RETAINER AND HOUSING
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
Fig. 123 INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
3 - BEARING RETAINER
Fig. 124 BEARING RETAINER BOLTS
1 - RETAINER BOLTS
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MANUAL - NV3500
21 - 71
MANUAL - NV3500 (Continued)
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