Dodge Dakota (R1). Manual — part 739

tor switch position is changed, or if diagnostic rou-
tines no longer allow the requested shift.

• If the driver attempts to make a shift into trans-

fer case NEUTRAL, and any of the driver controlla-
ble conditions are not met, the request will be
ignored until all of the conditions are met or until
the NEUTRAL select button is released. Additionally
the neutral lamp will flash, or begin to flash while
the button is depressed and operator controllable
conditions are not being met. All of the LED’s except
the Neutral will flash if any of the operator control-
lable conditions for shifting are not met while the
Neutral button is depressed. This

9toggle9 type of fea-

ture is necessary because the TCCM would interpret
another request immediately after the shift into
transfer case NEUTRAL has completed.

• No LED’s illuminated indicate a fault in the

transfer case control system.

SHIFT MOTOR

DESCRIPTION

The shift motor (Fig. 90) consists of a permanent

magnet D.C. motor with gear reduction to convert a
high speed-low torque device into a low speed-high
torque device. The output of the device is coupled to
a shaft which internally moves the mode and range
forks that change the transfer case operating ranges.
The motor is rated at 25 amps maximum at 72° F
with 10 volts at the motor leads.

OPERATION

The transfer case shift motor responds to the

Transfer Case Control Module (TCCM) commands to
move the transfer case shift sector bi-directionally, as
required, to obtain the transfer case operating mode
indicated by the instrument panel mounted selector
switch.

REMOVAL

(1) Raise the vehicle on a suitable hoist.
(2) Remove the front propeller shaft. (Refer to 3 -

DIFFERENTIAL

&

DRIVELINE/PROPELLER

SHAFT/PROPELLER SHAFT - REMOVAL)

(3) Disengage the wiring connectors from the shift

motor and mode sensor.

(4) Remove the front output shaft companion

flange from the transfer case.

(5) Remove the bolts (Fig. 91) holding the shift

motor and mode sensor assembly onto the transfer
case.

(6) Separate the shift motor and mode sensor

assembly from the transfer case.

Fig. 90 Shift Motor - Shown Inverted

1 - TRANSFER CASE SHIFT MOTOR

Fig. 91 Remove the Shift Motor and Mode Sensor

Assembly Bolts

1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT

21 - 600

TRANSFER CASE - NV244

AN

SELECTOR SWITCH (Continued)

INSTALLATION

(1) Verify that the shift sector o-ring is clean and

properly positioned over the shift sector and against
the transfer case.

(2) Position the shift motor and mode sensor

assembly onto the transfer case.

(3) Install the bolts (Fig. 92) to hold the assembly

onto the transfer case. Tighten the bolts to 16-24
N·m (12-18 ft.lbs.).

CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
Mopar® Lock & Seal or Loctite™ 242 to replenish
the lock patch material originally found on the bolts

(4) Engage the wiring connectors to the shift motor

and mode sensor.

(5) Install the transfer case front output shaft

companion flange onto the transfer case. Tighten the
flange nut to 122-176 N·m (90-130 ft.lbs.).

(6) Install the front propeller shaft. (Refer to 3 -

DIFFERENTIAL

&

DRIVELINE/PROPELLER

SHAFT/PROPELLER SHAFT - INSTALLATION)

(7) Refill the transfer case as necessary.
(8) Lower

vehicle

and

verify

transfer

case

operation.

Fig. 92 Install the Shift Motor and Mode Sensor

Assembly Bolts

1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT

AN

TRANSFER CASE - NV244

21 - 601

SHIFT MOTOR (Continued)

MANUAL - AX15

TABLE OF CONTENTS

page

MANUAL - AX15

. . . . . . . . . . . . . . . . . . . . . . . . . . 1

MANUAL - AX15

TABLE OF CONTENTS

page

page

MANUAL - AX15

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 3

MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . 3

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 32
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 33

BEARING RETAINER

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

EXTENSION HOUSING SEAL

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

COUNTERSHAFT

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INPUT SHAFT

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

OUTPUT SHAFT

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

MANUAL - AX15

DESCRIPTION

Vehicles equipped with the 2.5L turbo diesel engine

and manual transmission utilize the AX15. The
transmission

is

a

5-speed

synchromesh

manual

transmission. Fifth gear is an overdrive range with a
ratio of 0.79:1. The shift mechanism is integral and
mounted in the shift tower portion of the adapter
housing (Fig. 1).

Correct lubricant level is from the bottom edge, to

no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.

The fill plug is located on the driver’s side of the

transmission case (Fig. 2). The drain plug is located
on the passenger side of the transmission case near
the bottom (Fig. 3).

OPERATION

The manual transmission receives power through

the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission. At this point, all the transmission gears are
spinning.

The driver selects a particular gear by moving the

shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shift lever
moves the selected shift rail, the shift fork attached
to that rail begins to move. The fork is positioned in
a groove in the outer circumference of the synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer does
this by having the synchronizer hub splined to the
mainshaft, or the countershaft in some cases.

R1

MANUAL - AX15

21a - 1