DODGE TRUCK 1993 Service Repair Manual

21
- 10
NV4500
TRANSMISSION
OVERHAUL

SPECIAL TOOL
6459
SPECIAL TOOLS

6444-3
(3
REQD.)

THRUST
WASHER PIN THRUST
WASHER
(CONE SHAPED)
J9221-98
J9221-100

Fig.
18 Countershaft Rear Bearing Thrust
Washer
Removal

(11) Remove mainshaft fifth gear with Puller Tool
Set 6444 as follows:
(a) Position first Puller Jaw 6459 on gear (Fig.

19).
nr m

Fig.
20 Seating Puller Flange In First Puller Jaw SPECIAL TOOL

6444-8

J9221-101

Fig.
21 Installing Retaining Collar
Over
Puller
Jaws
SPECIAL TOOL
6444-8

1 MAINSHAFT
J9221-99
Fig.
19 Installing First Puller Jaw On Mainshaft
Fifth

Gear

(b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 20).
(c) Slide assembled puller flange and rods onto
output shaft. Then seat flange in notch of puller
jaw (Fig. 20).
(d) Position second Puller Jaw 6459 on gear and
in notch of puller flange (Fig. 21). (e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 21). (f) Install Puller and Bolt 6444 on puller rods.
Then secure puller to rods with retaining nuts (Fig.
22).
SPECIAL TOOL

6459

SPECIAL TOOL
6444

MAINSHAFT SPECIAL TOOL
6444-3
HOLDING
WRENCH
J9221-190

Fig.
22
Removing
Fifth
Gear
From
Mainshaft
Splines

(g) Tighten puller bolt to remove gear from shaft
splines (Fig. 22).

•

NV4500
TRANSMISSION OVERHAUL
21 - 11 (12) Remove bolts attaching mainshaft rear bear­
ing plate to gear case and remove fifth gear, plate,
end play shims and bearing cup (Fig. 28), .
MAINSHAFT REAR

BEARING
CUP
BEARING

SHIMS
BEARING

PLATE
FIFTH GEAR

J9221-102

Fig.
23 Removing Mainshaft Fifth
Gear,
Bearing Plate, Bearing Shims And Rear Bearing Cup FRONT RETAINER REMOWAL AND
DISASSEMBLY (1) Remove front retainer bolts (Fig. 24).

FRONT
BEARING
RETAINER
J9221-103

Fig.
24
Removing
Front Bearing Retainer
Bolts

(2) Remove front retainer by lightly tapping it
back and forth with plastic mallet to loosen it. Then rock retainer back and forth by hand to work it out
of gear case. Note that retainer flange extends into and is fairly snug fit in case bore.
(3) Remove seal from front retainer (Fig. 25). Use
small chisel to collapse one side of seal then pry it
out with suitable tool.
(4) Remove bearing cup from front retainer as fol­

lows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 26).
(b) Insert Puller Jaws 6453-1 in puller flange
(Fig. 26). Narrow lip of puller jaws will go under
bearing cup.
(c) Install assembled tools in front retainer (Fig.

27).
Be sure puller jaws are seated under bearing cup.
(d) Place Insert Tool 6453-2 in center of puller
jaws (Fig. 27). Insert tool is used to hold puller
jaws in place.
FRONT
BEARING

RETAINER
SEAL

Fig.
25 Removing Bearing Retainer
Seal

SPECIAL
TOOL

6453-1
SPECIAL

TOOL

6444-4

SPECIAL
TOOL

6444-1

J9221-178X

Fig.
26
Assembling
Puller
Rods,
Flange And
Jaws
SPECIAL
TOOL

6453
SPECIAL

TOOL

6453-2

FRONT

RETAINER
J9221-179
Fig.
27 Installing Puller Tools In Front Retainer

21-12
NV45Q0
TRANSMISSION
OVERHAUL

• (e) Install Puller 6444 on puller rods (Fig. 28).
Then install retaining nuts on puller rods. (f) Tighten puller bolt to draw bearing cup out of
retainer (Fig. 28). Use holding wrench on puller and turn puller bolt with adjustable wrench.
TIGHTENING

WRENCH
HOLDING

WRENCH

SPECIAL
TOOL

6453-2

FRONT

RETAINER
J922M80

Fig.
28
Removing
Bearing Cup From Front Retainer DRIVE GEAR REMOVAL AND DISASSEMBLY
(1) Remove drive gear. Tilt gear downward and out
of case (Fig. 29).
(2) Remove pilot bearing from drive gear (Fig. 30).
(3) Remove bearing from drive gear as follows:
J9221-105
DRIVE
GEAR

MAINSHAFT

PILOT
BEARING

J9221-106
Fig.
30 Pilot Bearing Removal/Installation
(a) Note that puller tool assembly and setup is
similar to that used for removing fifth gear from
mainshaft (Figs. 19-23). (b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-4. Then position first Puller Jaw 6447
on gear (Fig. 31).
(c) Slide assembled puller flange and rod tools
onto output shaft. Then seat flange in notch of
puller jaw (Fig. 31). (d) Position second Puller Jaw 6447 on gear and
in notch of puller flange (Fig. 31).
SPECIAL
TOOL

6444

DRIVE
GEAR

SPECIAL
TOOL

6444-1
SPECIAL

TOOLS

6444-6
(3)

SPECIAL
TOOLS
6447
(2)

Fig.
29 Drive Gear
Removal
SPECIAL
TOOL

6444-8

J9221-115X

Fig.
31
Removing
Front Bearing From Drive Gear

+

MAINSHAFT AND GEARTRAIN REMOVAL
(1) Remove countershaft rear bearing plate (Fig.

32).

Fig.
32
Removing
Countershaft Rear Bearing
Plate
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33).
Fig.
33 Countershaft End Play
Shim
And Rear

Bearing
Cup
Removal
(3) Remove reverse idler shaft. Thread a shift
cover bolt into shaft and withdraw shaft from case (Fig. 34).
(4) Move 1-2 and 3-4 synchro sleeves into Neutral,
if necessary.
(5)
Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 35).
(6) Remove fourth speed clutch gear and synchro
stop ring from mainshaft (Fig. 36).
N¥4S0O
TRANSMISSION
OVERHAUL
21 - 13

Fig.
34
Removing
Reverse
Idler Shaft

Fig.
35 Drive Gear Thrust Bearing
Removal

Fig.
36 Fourth
Speed
Clutch
Gear
Stop
Ring
Removal
(7) Roll gear case onto left side (Fig. 37).
(8) Reach into gear case and push reverse idler
gear away from mainshaft gears.
(9) Remove mainshaft assembly as follows (Fig.

37):
(a) Lift front end of mainshaft slightly.
(b) Grasp mainshaft rear splines. Then turn
spline end of mainshaft in counterclockwise direc­
tion to rotate shaft and geartrain out of case.
(c) Once mainshaft gears roll clear of counter­
shaft gears, shaft and gear assembly can be tilted
outward and removed from gear case (Fig. 37).
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 31).
(f) Install Puller 6444 on puller rods. Then se­
cure puller to rods with retaining nuts (Fig. 31).
(g) Tighten puller bolt to remove bearing cone
from drive gear (Fig. 31).

21
- 14
NV4500
TRANSMISSION OVERHAUL
Fig.
37 Mainshaft And
Geartrain
Removal
(10) Refer to mainshaft disassembly procedures if
any gears or synchro components must be replaced.

REVERSE IDLER GEAR
AMD
COUNTERSHAFT

REMOVAL/DISASSEMBL
¥
(1) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 38).

Fig.
38
idler
Gear
Moved
Away
From Countershaft (2) Remove idler gear through drive gear bore at
front of case (Fig. 39).
(3) Keep reverse idler gear bearings and spacer to­
gether for cleaning and inspection (Fig. 40). Insert
idler shaft through gear and bearings to keep them
in place.
(4) Remove idler gear thrust washers from gear

case.
Install washers on idler shaft to keep them to­
gether for cleaning and inspection.
(5) Remove countershaft rear bearing. Shaft can­
not be removed from case until rear bearing has been
removed. Bearing removal procedure is as follows: (a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 41). •
J922M14

Fig.
39
Reverse
Idler Gear
Removal
REVERSE

BEARINGS IDLER
Fig.
40
Reverse
Idler Gear
Components
(b) Position first Puller Jaw 6449 on bearing
cone (Fig. 41).
(c) Seat puller flange in notch of puller jaw just
installed on bearing cone (Fig. 41).
(d) Install second Puller Jaw 6449 on bearing
and in notch of puller flange (Fig. 41). (e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 41). Note that re­ taining collar has small lip on one end and only
fits one way over jaws.
Fig.
41
Removing
Countershaft Rear Bearing

•

NV4500
TRANSMISSION OVERHAUL
21 - 15 (f) Install Puller 6444 on puller rods. Then se­
cure puller to rods with retaining nuts (Fig. 41). (g) Tighten puller bolt to remove bearing from
shaft (Fig. 41). If bearing is exceptionally tight, tap
end of puller bolt with copper mallet to help loosen
bearing.
(6) Remove bearing puller tools.
(7) Rotate countershaft out of gear case (Fig. 42).
Fig.
42
Removing
Countershaft From Gear
Case

(8) Remove countershaft front bearing as follows:
(a) Assemble Puller Flange 6444-1 and Puller
Bolts 6444-6 (Fig. 43).
(b) Position first Puller Jaw 6451 on bearing. (c) Seat puller flange in notch of puller jaw.
(d) Install second Puller Jaw 6451 on bearing
and in notch of puller flange.
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 43). Note that re­ taining collar has small lip on one end and only
fits one way over jaws. (f) Install Puller Bridge And Bolt Assembly 6444
on puller bolts. Then secure bridge to bolts with re­
taining nuts (Fig. 43). J922M 59X
6444-4

Fig.
43
Removing
Countershaft Front Bearing (g) Tighten puller bolt to remove bearing from
shaft (Fig. 43). If bearing is exceptionally tight, tap
end of puller bolt with mallet to help loosen bear­ ing.
(9) Remove bearing puller tools.
(10) Set countershaft and idler gear aside for
cleaning and inspection.
GEAR CASE DISASSEMBL¥ (1) Remove countershaft front bearing cap. Use
mallet or hammer to remove cap from inside case (Fig. 44).
Fig.
44 Countershaft Front Bearing Cap
Removal

(2) Remove countershaft front bearing cup with
Remover Tool 6454 and Tool Handle C-4171 (Fig.

45).
Fig.
45 Countershaft Front Bearing Cup
Removal
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 46). A small pin punch can be mod­ ified by putting a slight bend in it to drive pin com­
pletely out of shift rail (Fig. 46).
(4) Remove shift lug rail by tapping it out of case
and shift lug with tapered punch (Fig. 47). Note po­
sition of rail and lug for assembly reference.
(5) Remove lug rail bushings from gear case with
Special Tool 6456 (Fig. 48).
(6) Unclip and remove magnet from bottom of gear
case (Fig. 49).

21
- 16
NV4500
TRANSMISSION
OVERHAUL

Fig. 46 Removing Shift Lug Roii Pin Fig. 4?
Removing
Shift Lug Rali
Fig. 48 Removing Shift Lug Rail Bushings Fig. 49 Gear Case Magnet Location chro components can be installed backwards.
To avoid reassembly problems, mark the speed
gears,
clutch gears, synchro hubs, and sleeves
for reference during teardown. Use paint or a scriber for marking purposes.
Then
stack the
geartrain parts in
order
of removal. This prac­
tice
will
help avoid incorrect assembly and lost

time.

(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Remove fourth gear synchro struts and springs
from 3-4 hub and sleeve (Fig. 50). Three struts and springs are used. Keep springs and struts together
for inspection and cleaning. Store parts in a paper
cup to avoid losing them.
Fig. 50 3-4 Synchro Strut And Spring Removal
(3) Remove 3-4 sleeve from 3-4 synchro hub (Fig.

51).

(4) Remove 3-4 synchro hub from mainshaft
splines with suitable size bearing splitter, or with
two tapered drifts. Position splitter or drifts between third gear stop ring to start moving hub off shaft.
Then complete hub removal by tapping it off shaft with plastic mallet. Tap hub at 6-8 different points to
remove hub evenly.
MAINSHAFT
DISASSEMBLY
Not all of the mainshaft gear and synchro com­
ponents are a one-way fit. Some gear and syn-

NV4500
TRANSMISSION OVERHAUL
21 - 17

J922M19

Fig.
51
Removing
3-4
Sieeve
From Hub
THIRD

GEAR

NEEDLE

BEARING

ASSEMBLIES

THIRD
GEAR

THIRD
GEAR STOP

RING
J922M21

Fig.
53 Third Gear Needle Bearing
Removal
SECOND
GEAR
THRUST
WASHER

THRUST

WASHER

SNAP
RING

THIRD
GEAR
BEARING
SPACER
3-4

SYNCHRO
HUB
J9221-122

Fig.
54 Bearing
Spacer
And
Snap
Ring
Location
SECOND
GEAR
J922M20

Fig.
52 Third Gear,
Stop
Ring
And 3-4 Hub
Removal
(5) Remove 3-4 synchro hub, third gear stop ring
and third gear (Fig. 52). (6) Remove third gear bearing assemblies from
mainshaft (Fig. 53). (7) Remove third gear bearing spacer (Fig. 54).
(8) Remove snap ring that retains second gear
thrust washer on mainshaft (Fig. 54). (9) Remove second gear thrust washer (Fig. 55).
Note that washer is notched for locating pin.
THRUST

WASHER

SECOND GEAR

BEARING
J9221-123

Fig.
55
Second
Gear Thrust
Washer
Removal

21-18
NV4500
TRANSMISSION
OVERHAUL

Fig.
56
Second
Gear
Removal

Fig.
57
Second
Gear Bearing
Removal

Fig.
58 Thrust
Washer
Locating Pin
Removal
(10) Remove second gear (Fig. 56).
(11) Remove second gear bearing assembly (Fig.

57).
•

J922M27

Fig.
59
Removing
Second
Speed
Clutch
Gear
Snap
Ring

Fig.
60
Second
Speed
Clutch
Gear,
Clutch
Ring
And
Stop
Ring
Removal
(13) Remove snap ring that retains second speed
clutch gear (Fig. 59). Snap ring is seated in main-
shaft synchro hub groove. (14) Remove second speed clutch gear, synchro
clutch ring and synchro stop ring (Fig. 60).
(15) Remove 1-2 synchro hub snap ring (Fig. 61).
(16) Mark position of 1-2 synchro sleeve and hub
for assembly reference. Side of hub with flat hub spring goes toward front (Fig. 62). Note that tapered side of sleeve also goes toward front.
(17) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 62). It is not necessary
to disassemble synchro components unless worn, or damaged.
(18) Remove first gear synchro stop ring and
clutch ring (Fig. 63).
(19) Remove first speed clutch gear front snap ring
from mainshaft hub (Fig. 64). (20) Remove first speed clutch gear (Fig. 65). (12) Remove thrust washer locating pin (Fig. 58).
Use needle nose pliers to grip and remove pin.

NV4500
TRANSMISSION OVERHAUL
21 - 19

J9221-129

Fig. 81 Hemming 1-2 Sleeve And Hub Snap Ring 1-2

SLEEVE

AND
HUB
(MARK

POSITION
FOR
ASSEMBLY

REFERENCE)

HUB
SPRING
J9221-130

Fig. 62 Removing 1-2 Synchro Sleeve And Hub

FIRST
GEAR

CLUTCH
RING

FIRST
GEAR
STOP
RING
J922M31

Fig.
63 First Gear
Stop
And
Clutch
Ring
Removal

(21) Remove first speed clutch gear rear snap ring
from mainshaft hub (Fig, 65). It is not really neces­ sary to remove this snap ring unless it, or the main-shaft is to be replaced.

(22)
Remove mainshaft rear bearing as follows:
FIRST

SPEED

CLUTCH
GEAR
CLUTCH

GEAR

SNAP
RING

(FRONT)

J922M32

Fig.
64 First
Speed
Clutch
Gear Front
Snap Ring
Removal

CLUTCH GEAR

SNAP
RING (REAR) FIRST

SPEED

CLUTCH
GEAR
J9221-133

Fig.
65 First
Speed
Clutch
Gear
Removal

(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 66).
(b) Position first Puller Jaw 6445 on bearing
cone (Fig. 66).
(c) Seat Puller Flange 6444-1 in notch of first
puller jaw (Fig. 66).
(d) Install second Puller Jaw 6445 on bearing
cone and on puller flange (Fig. 66).
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 67). Note that re­ taining collar has small lip on one end and only
fits one way over jaws.
(f) Install Puller 6444 on puller rods. Then se­
cure puller to rods with retaining nuts (Fig. 67).
(g) Place holding wrench on hex at top of puller
(Fig. 67). Then tighten puller bolt with adjustable
wrench to remove bearing from shaft (Fig. 67). If
bearing proves difficult to remove, tap end of puller bolt with copper hammer after each turn of bolt.
This will help loosen bearing on shaft and ease re­ moval.