Dodge Dakota (R1). Manual — part 594
NOTE: The synchro hub is a press fit design. There
may be instances where the press is not necessary.
As long as there is a snug fit between the hub and
the shaft, the hub does not need to be replaced.
(29) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe tool (Fig. 59).
Press tool must be as close to the hub center as pos-
sible but not contacting the shaft splines.
(30) Install 3-4 synchro hub new snap ring (Fig.
60) with thickest snap ring that will fit in shaft
groove. Verify snap ring is seated in groove.
(31) Verify position of synchro sleeves before pro-
ceeding (Fig. 61).
Fig. 58 START 3-4 SYNCHRO HUB ON OUTPUT
SHAFT
1 - GROOVED SIDE OF SLEEVE (TO FRONT)
2 - 3-4 SYNCHRO ASSEMBLY
Fig. 59 PRESS 3-4 SYNCHRO ASSEMBLY ON
SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 60 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
21 - 20
MANUAL - NV1500
AN
MANUAL - NV1500 (Continued)
GEARTRAIN
(1) Install input shaft into Support Stand 8355
(Fig. 62).
(2) Install pilot bearing in input shaft (Fig. 62).
(3) Install fourth gear synchro ring on input shaft
(Fig. 63).
(4) Install assembled output shaft and geartrain in
input shaft (Fig. 64). Rotate output shaft until the
3-4 synchro ring seats in synchro hub and sleeve.
(5) Slide countershaft into fixture slot. Verify coun-
tershaft and output shaft gears are fully meshed
with the mainshaft gears (Fig. 65).
(6) Thread one Pilot Stud 8120 in center or pas-
senger side hole of output shaft bearing retainer.
Then position retainer on fifth gear.
(7) Assemble 1-2 and fifth reverse-shift forks (Fig.
66). Arm of fifth-reverse fork goes through slot in 1-2
fork.
Fig. 61 SYNCHRO SLEEVE POSITION
1 - 2 GROOVES
2 - 1 GROOVE
3 - 2 GROOVES
4 - FOURTH GEAR
5 - THIRD GEAR
6 - SECOND GEAR
7 - FIRST GEAR
8 - REVERSE GEAR
9 - FIFTH GEAR
Fig. 62 INPUT SHAFT AND PILOT BEARING
1 - PILOT BEARING
2 - INPUT SHAFT
3 - STAND 8355
AN
MANUAL - NV1500
21 - 21
MANUAL - NV1500 (Continued)
(8) Install assembled shift forks in synchro sleeves
(Fig. 67). Verify forks are seated in sleeves.
Fig. 63 FOURTH GEAR SYNCHRO RING ON INPUT
SHAFT
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
3 - STAND 8355
Fig. 64 MAINSHAFT ON SUPPORT STAND
1 - MAIN SHAFT
2 - SUPPORT STAND 8355
Fig. 65 COUNTERSHAFT ON SUPPORT STAND
1 - COUNTER SHAFT
2 - MAIN SHAFT
3 - SUPPORT STAND 8355
Fig. 66 1-2 AND FIFTH-REVERSE SHIFT FORKS
1 - INSERT ARM THROUGH 1-2 FORK
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
21 - 22
MANUAL - NV1500
AN
MANUAL - NV1500 (Continued)
REAR HOUSING
(1) Lubricate countershaft rear bearing race.
(2) Install rear housing onto geartrain (Fig. 68).
Verify bearing retainer pilot stud is in correct bolt
hole and countershaft and output shaft bearings are
aligned in housing and on countershaft.
(3) Seat rear housing on output shaft rear bearing
and countershaft. Tap housing into place with plastic
or rawhide hammer.
(4) Apply Mopar® Gasket Maker or equivalent to
bolt threads, bolt shanks and under bolt heads (Fig.
69).
(5) Start first two bolts in retainer (Fig. 70). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts.
(6) Remove
Pilot
Stud
8120
and
install
last
retainer bolt (Fig. 70).
(7) Tighten all three retainer bolts to 22 N·m (16
ft. lbs.).
NOTE: All bolts except the reverse idler shaft bolts
have o-rings to seal the bolts to the transmission
case. Inspect the o-rings to ensure that they are in
good condition.
REVERSE IDLER
(1) Remove geartrain and housing assembly from
support stand with aid of helper.
(2) Assemble shaft, gear and washer (without
bearing or support) and install into housing (Fig. 71).
Fig. 67 SHIFT FORKS AND SYNCHROS
1 - FIFTH REVERSE SHIFT FORK
2 - 1-2 SHIFT FORK
Fig. 68 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 69 RETAINER AND HOUSING BOLTS
1 - MOPAR GASKET MAKER
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
AN
MANUAL - NV1500
21 - 23
MANUAL - NV1500 (Continued)
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