air DODGE RAM 1500 1998 2.G Workshop Manual

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
DIAGNOSIS AND TESTING - STEERING
COLUMN.............................7
REMOVAL.............................7
INSTALLATION..........................9
IGNITION SWITCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................9
REMOVAL.............................10
INSTALLATION.........................11
KEY-IN IGNITION SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......11
KEY CYLINDER
REMOVAL.............................12
INSTALLATION.........................12GEAR SHIFT LEVER
REMOVAL.............................12
INSTALLATION.........................12
UPPER STEERING COUPLING
REMOVAL.............................13
INSTALLATION.........................13
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD...................14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD.................................14
INSTALLATION - 4X4 HD................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
TILT LEVER KNOB RELEASE
REMOVAL.............................16
INSTALLATION.........................16
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT INACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
19 - 6 COLUMNDR

NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col-
lapsed. Inspect the column mounting capsules visu-
ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the front wheelsstraight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the two switches from the steering
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98±1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever.
(8) Remove the column shrouds (Fig. 2).
(9) Remove the clock spring, (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
(10) Disconnect the wiring harness to the column.
Fig. 1 STEERING COLUMN
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DRCOLUMN 19 - 7
COLUMN (Continued)

(17) Remove the steering column assembly from
the vehicle. (Fig. 7)
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install anewbolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N´m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N´m (42 ft. lbs.).(6) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(7) Install the shifter cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column.
(9) Install the SKIM module.
(10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds.
(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(13) Align the spline on the wheel hub to shaft.
(14) Then install the steering wheel and install a
newbolt. Tighten the bolt to 61 N´m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches.
(17) Install the tilt lever handle.
(18) Install the negative battery terminal.
(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.
IGNITION SWITCH
DESCRIPTION
The ignition switch is located on the steering col-
umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
Fig. 7 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DRCOLUMN 19 - 9
COLUMN (Continued)

HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.
REMOVAL
SERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped
with an automatic transmission is not equipped
with an internal locking shaft with the ignition cyl-
inder. Alternative methods of locking the steering
wheel for service will have to be used.
The tilt and standard column (Fig. 8) have been
designed to be serviced as an assembly; without wir-
ing, switches, shrouds, steering wheel, etc. Most
steering column components can be serviced without
removing the steering column from the vehicle.
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag,
Refer to Electrical Restraints and follow all WARN-
INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG ANDPOSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism.
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) Remove the negative (ground) cable from the
battery.
(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(3) Remove the lower and upper shrouds.
(4) Remove key cylinder. (Refer to 19 - STEER-
ING/COLUMN/LOCK CYLINDER HOUSING -
REMOVAL).
(5) Disconnect the lower clockspring connectors.
(6) Remove the wire retainer from the tilt lever
bracket.
(7) Remove the tilt lever mounting screws to gain
access to the ignition switch mounting screws. (Fig.
9)
Fig. 8 STEERING COLUMN
1 - KEY CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - IGNITION SWITCH
Fig. 9 IGNITION SWITCH WITH TILT
1 - IGNITION SWITCH
2 - TILT LEVER MECHANISM
19 - 10 COLUMNDR
IGNITION SWITCH (Continued)

(8) For columns without tilt remove the bracket to
gain access to the ignition switch mounting screws.
(Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
(10) Remove ignition switch mounting screw.
(11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.(2) Connect the electrical connector to rear of the
ignition switch. Make sure that locking tabs are fully
seated into wiring connector.
(3) Position switch to column and install the
mounting screw. Tighten screw to 3 N´m (26 in. lbs.).
(4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N´m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N´m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
(7) Reconnect the lower clockspring connectors.
(8) Install the key cylinder.
(9) Install steering column upper and lower
shrouds.
(10) Enable the airbag system. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION).
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition key cylinder and the driver
door ajar switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition key cylinder.
The ground path is also opened when the driver door
ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri-
cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
Fig. 10 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 11 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
DRCOLUMN 19 - 11
IGNITION SWITCH (Continued)

(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear.
(2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 28
N´m (250 in. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
STEERING WHEEL
REMOVAL
(1) Disable and remove the driver's side air-
bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 61 N´m (45 ft. lbs.).
(3) Install the driver's side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DRCOLUMN 19 - 15
LOWER STEERING COUPLING (Continued)

(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensing switch is used in the power
steering system. It is mounted on the high-pressure
steering hose (Fig. 9). This switch will be used with
both 3.7L and 5.7L engines. There is no pressure
switch used for the 4.7L or the 5.9L pump.
OPERATION
The switch is used on the 3.7L V-6 & 5.7L V-8
engines.
The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
input is provided during periods of high steering
pump load and low engine rpm; such as during park-
ing maneuvers. The PCM increases the idle speed
through the Idle Air Control (IAC) motor. This is
done to prevent the engine from stalling under the
increased load.
When steering pump pressure exceeds 3275 kPa  
690 kPa (475 psi   100 psi), the Normally Closed
(NC) switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.
REMOVAL - 3.7L & 5.7L
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Disconnect electrical connector from power
steering pressure switch.(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 3.7L & 5.7L
This switch is used only with the 3.7L V±6 and the
5.7L V-8 engines.
(1) Install power steering switch into power steer-
ing line.
(2) Tighten to 8±11 N´m (70±100 in. lbs.) torque.
(3) Connect electrical connector to switch.
(4) Check power steering fluid and add as neces-
sary.
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
Fig. 9 PRESSURE SWITCH
1 - POWER STEERING PULLEY
2 - POWER STEERING PUMP HOUSING
3 - POWER STEERING FLUID RESERVOIR
4 - RETURN HOSE
5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
19 - 46 PUMPDR
HOSES - LINK/COIL (Continued)

(16) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 45).
(17) Remove reverse gear and needle bearing (Fig.
46).
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
Fig. 45 FIFTH-REVERSE SYNCHRO
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 46 REVERSE GEAR & NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
Fig. 47 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
DRMANUAL TRANSMISSION - NV3500 21 - 15
MANUAL TRANSMISSION - NV3500 (Continued)

Inspect output shaft bearing retainer, the
U-shaped retainer must be flat and free of distortion.
Replace the retainer if the threads are damaged or if
the retainer is bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, the front or rear hous-
ing must be replaced. A new countershaft bearing
will be supplied with each new housing for service
use.
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing if any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted or brinnelled. Also
replace the bearing if the plastic bearing cage is
damaged or distorted.
Replace thrust washer, wave washer or thrust
plate if cracked, chipped or worn. Replace idler gear
if the teeth are chipped, cracked or worn thin.
Replace shaft if worn, scored or the bolt threads are
damaged beyond repair. Replace support segment if
cracked or chipped and replace the idler attaching
bolts if the threads are damaged.
Shift Socket
Inspect the shift socket for wear or damage.
Replace the socket if the roll pin or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn or cracked. Do not reuse the original
shift socket roll pin. Install anewpin during assem-
bly. The socket roll pin is approximately 33 mm
(1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro-
ken teeth. Also check condition of the bearing bore in
each gear. The bores should be smooth and free of
surface damage. Discoloration of the gear bores is a
normal occurrence and is not a reason for replace-
ment. Replace gears only when tooth damage has
occurred or if the bores are brinnelled or severely
scored.
Inspect the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-aged or bearing surfaces are deeply scored, worn or
brinnelled.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use
Mopar Gasket Maker or equivalent for all case joints
and Mopar silicone sealer or equivalent for the
input shaft bearing retainer.
SYNCHRONIZER
(1) Slide sleeve onto the hub, leaving enough room
to install the spring in the hub and strut in the hub
groove.
(2) Install first spring in the hub, then install a
strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide sleeve onto the hub far enough to hold
the first strut and spring in place.
(4) Place detent ball in the top of the strut, then
press the ball into place with a small screwdriver.
Work the sleeve over the ball to hold it in place.
(5) Repeat procedure for the remaining springs,
struts and balls. Use tape or rubber bands to tempo-
rarily secure each strut and ball as they are
installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 49).
Fig. 49 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
DRMANUAL TRANSMISSION - NV3500 21 - 17
MANUAL TRANSMISSION - NV3500 (Continued)

(28) Remove reverse clutch gear (Fig. 62).
(29) Remove first gear from bearing and mainshaft
(Fig. 63).
(30) Remove first gear bearing from mainshaft
(Fig. 64).
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Replace the gear if the teeth are chipped, cracked or
worn thin.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Replace the retainer if worn or
damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap
ring grooves and threads. Replace the shaft if any
surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or
damage.
Inspect shift forks for wear and distortion. Check
fit of the sleeve in the fork to be sure the two parts
fit and work smoothly. Replace the fork if the roll pin
holes are worn oversize or damaged. Do not attempt
to salvage a worn fork. Replace shift fork roll pins if
necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots,
pitting or other damage. Replace the bearings if nec-
essary.
Inspect the blocker rings and fiction cones. replace
either part if worn or damaged in any way. Replace if
the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the wash-
ers if worn or the locating pin notches are distorted.
Inspect the case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. InspcetFig. 62 Reverse Clutch Gear
1 - REVERSE CLUTCH GEAR
Fig. 63 FIRST GEAR
1 - FIRST GEAR
Fig. 64 FIRST GEAR BEARING
1 - MAINSHAFT
2 - FIRST GEAR BEARING
21 - 62 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)