DODGE TRUCK 1993 Service Repair Manual

21
- 40
NV4500
TRANSMISSION
OVERHAUL

SPECIAL

TOOL
6443
FIFTH

GEAR

NUT

SPECIAL
TOOL
6441
OR

6442

RATCHET

WRENCH
BREAKER

BAR

J9221-92

Fig.
149 Fifth Gear
Nut
installation (6) Lock mainshaft gears
by
shifting
all
synchro
sleeves into engaged position, (7) Position Spline Socket Wrench
6441 or
6442
on

mainshaft splines. Then install breaker
bar in
socket
wrench
and
wedge
bar
against workbench. (8) Tighten fifth gear
nut
with
Nut
Wrench 6443
and high capacity torque wrench. Required torque
on

nut
is
339-475
N*m
(250-350
ft.
lbs.). Have helper
hold transmission steady
if
necessary.
Nut can
also
be tightened
by
striking Wrench 6443 with heavy- copper mallet then checking with torque wrench.

COUNTERSHAFT
FIFTH
GEAR
AND
SYNCHRO

INSTALLATION
(1) Install thrust washer
pin in
countershaft
(Fig.

150).
0/

COUNTERSHAFT

J9221-234

Fig.
150 Installing Fifth Gear Thrust Washer Pin (2) Install thrust washer
on
countershaft. Turn
washer until
pin
engages
in
washer notch
(Fig. 151).
Flat side
of
washer faces rear
and
cone side
to
front as shown.
J9221-235

Fig.
151 installing
Fifth
Gear Thrust
Washer
(3) Lubricate
and
install fifth gear bearings
on

countershaft
(Fig. 152).

(4) Install bearing spacer
on
countershaft
and
seat
it against bearings
(Fig. 152).
Coat spacer with
pe­

troleum jelly
to
hold
it in
place.
.BEARING

SPACER
FIFTH

GEAR

BEARINGS
J9221-236

Fig.
152 Countershaft
Fifth
Gear Bearing And
Spacer
Installation
(5) Install synchro sleeve
on hub of
countershaft
fifth gear. Tapered side
of
sleeve faces front
and
flat side faces rear
(Fig. 153).
GEAR

SYNCHRO

SLEEVE

COUNTERSHAFT
FIFTH

GEAR

J9221-237

Fig.
153 Installing
Synchro
Sleeve
On
Countershaft
Fifth
Gear
Hub
(6) Install shift fork
in
synchro sleeve
(Fig. 154).

(7) Install assembled fifth gear, synchro sleeve
and

shift fork
(Fig. 155).
Align fork with shift
lug
rail and align gear with bearings
and
countershaft. Start

•

NV4500
TRANSMISSION
OVERHAUL
21 - 41
SYNCHRO

'
SLEEVE

SHIFT

FORK

V ^ .LS
J9221-238
Fig.
154 Installing
Fifth
Gear Shift
Fork
In
Synchro
Sleeve

components onto shaft and rail. Then tap gear and
fork into place with plastic or rawhide mallet. (8) Align roll pin holes in shift fork with notches
in shift lug rail. Then install roll pins from top side
of fork (Fig. 155). Note that roll pins are one way fit
due to small shoulder at one end of each pin.

Fig.
155 Installing
Assembled
Countershaft
Fifth
Gear, Shift
Fork
And
Synchro
Sleeve

(9) Install synchro struts and springs in fifth gear
hub (Fig. 156). Install struts in hub slots first. Then
install springs by compressing them with screwdriver
and working springs into hub and struts.
(10) Assemble and install fifth synchro clutch gear
and stop ring in fifth gear hub (Fig. 157). Make sure
both parts are seated in fifth gear hub. (11) Install clutch gear snap ring (Fig. 158).

EXTENSION/ADAPTER
HOUSING

INSTALLATION
(1) If extension housing seal needs replacement,
remove it collapsing with a punch and chisel. Then
pry seal out of housing with crowfoot pry bar. (2) If extension housing bushing must be replaced,
collapse old bushing with tapered drift (Fig. 159). Po­
sition drift in slot provided at end of housing. Then
tap drift into slot and against bushing to collapse and remove it.
Fig.
156 installing
Fifth
Gear
Synchro
Struts And

Springs
Fig.
157
Fifth
Synchro
Clutch
Gear And
Stop
Ring

Installation

CLUTCH

GEAR
J9221-89

Fig.
158 Installing
Fifth
Synchro
Clutch
Snap
Ring
(3) Remove any burrs from housing bushing bore
with a file and emery cloth.
(4) Install new bushing in extension housing (Fig.

160).
Use Tool Handle C-4171 and Installer Tool
SP5559 to install bushing. Note that installer tool
SP5559 is part of tool set C-4469.
(5) Install extension housing seal with Tool
C-4660-3 (Fig. 161).

21
- 42
NV4500
TRANSMISSION
OVERHAUL

TAPERED PUNCH
SPECIAL
TOOL

C-4660-3

BUSHING

EXTENSION HOUSING

J9221-251
Fig.
159
Removing
Extension
Housing Bushing
SPECIAL

-TOOL
C-4171

SPECIAL
•TOOL

C-4660-3

EXTENSION HOUSING
J9221-252
Fig.
160 Installing Extension
Housing Bushing

(6) Clean mating surfaces of extension/adapter
housing and gear case with a wax and grease re­
mover.
(7) Check alignment dowels in gear case and hous­
ing or adapter. Be sure dowels are in position and seated.
(8) Apply Mopar Gasket Maker to gear case and
housing mating surfaces.
(9) Align and install extension/adapter housing on
gear case (Fig. 162).
(10) Apply Mopar Lock N' Seal or Loctite 242 to
threads of extension/adapter housing bolts.
(11) Install and tighten housing bolts to 54 N» (40
ft. lbs.) torque. Use a twelve point 10 mm socket, a ratchet wrench and necessary extensions to in­
stall bolts. Do not use any other type of socket and do not use an impact wrench. Splines on
bolt heads can be damaged if impact wrench or wrong type of socket is used for tightening pur­

poses.
J9221-201

EXTENSION HOUSING

Fig.
161 Installing Extension
Housing Seal
EXTENSION HOUSING

GEAR
CASE
J9221-85
Fig.
162 Installing Extension/Adapter
Housing SHIFT COVER INSTALLATION

(1) Clean mating surfaces of shift cover and gear
case with a wax and grease remover.
(2) Apply Mopar Gasket Maker, or Loctite 518 to
sealing surface of shift cover or gear case. Do not
overapply sealer material. Excess can be squeezed
into gear case and could block lubricant feed holes in

time.

(3) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(4) Verify that 1-2 and 3-4 synchro sleeves are in
neutral position. Also verify that forks in shift cover are in neutral position.

•

NV4500
TRANSMISSION OVERHAUL
21 • 43 (5) Align and install shift cover (Fig. 163). If cover
will not seat, it is either not aligned on gear case
dowels, or shift forks are not aligned with sleeves and shift lug.

SHIFT

Fig.
163 Installing Shift
Cover
Assembly

(6) Apply Mopar Lock N' Seal or Loctite 242 to
threads of shift cover bolts. (7) Install and tighten shift cover bolts to 30 Nnn
(265 in. lbs.) torque.
(8) Install backup light switch and vent in shift
cover. Apply sealer to switch threads before installa­
tion and tighten switch to 30 Nnn (265 in. lbs.).
(9) On 2-wheel drive models, install and index
speedometer adapter in extension housing. (10) Install and tighten drain plug to 40 Nnn (30
ft. lbs.) torque.
(11) Fill transmission to bottom edge of fill plug
hole with Castrol Syntorq gear lubricant.
(12) Install and tighten fill plug to 40 N-m (30 ft.
lbs.) torque.

SHIFT
COVER SERVICE
The only serviceable shift cover components are:
• fifth-reverse shift fork pads
• reverse inhibitor
• vent components • backup light switch
• expansion plugs
• shift lever components The shift cover, shift forks, shift rails and detent
components are not serviced individually. The cover
must be replaced as an assembly if the cover, or any shift components are worn or damaged.

Shift
Cover
Inspection
Inspect the cover and shift components whenever
the cover is removed from the gear case. Or, when­ ever diagnosis indicates inspection is necessary.
Check the forks for wear, distortion, cracks, or be­
ing loose on the shift rails. Also check fit of the shift rails in the cover. Replace the cover assembly if the
rails are loose in the cover bores.
Inspect and replace the pads on the fifth-reverse
shift fork if worn. The reverse inhibitor should also
be replaced if worn, or faulty. The expansion plugs at
the rear of the cover can be replaced if loose or leak­ ing.
A gasket is not used between the shift cover
and gear case. Use Mopar Gasket Maker, or Loc­
tite 518 to seal the cover.
Procedures for the serviceable components in the
shift cover as follows:

Fifth-Reverse
Shift
Fork Pad Replacement The plastic shift fork pads are held in place by a
combination of tension and a small locating tang.
Three pads are used on the fork (Fig. 164).
The pads can be removed either by hand or with a
narrow blade screwdriver. To remove the pads by
hand, grasp each pad and tilt it out and off the fork.
If the pads prove difficult to remove by hand, insert a screwdriver blade between the pad and fork and pry
the pad off.

Fig.
164 Shift
Fork
Pad
Locations

Reverse
Inhibitor Replacement The reverse inhibitor mechanism should be
checked for wear or damage whenever diagnosis in­
dicates this is necessary.
The inhibitor mechanism is attached to the cover
with two screws (Fig. 165). Attaching screw torque is 8-14 N-m (75-115 in. lbs.).
Vent
Component
Replacement The shift cover vent assembly consists of the vent

tube,
connecting hose, hose clamps, and vent valve (Fig. 166).
If the vent tube is removed for replacement or ser­
vice access, apply Mopar silicone adhesive/sealer to
the tube to help secure it in the cover.

21
- 44
NV450Q
TRANSMISSION
OVERHAUL

REVERSE

INHIBITOR
J9221-255

Fig.
165
Reverse
Inhibitor
Mounting
HOSE

VENT

VALVE

VENT
TUBE
CLAMP
J9221-256

Fig.
166 Shift
Cover
Vent
Components

Backup
Light
Switch
Replacement
The backup light switch is located at the left (driv­
er) side of the cover (Fig. 167). The switch plunger is
operated by the fifth-reverse shift rail.
The switch can be replaced with the transmission
in, or out of the vehicle. A gasket may, or may not be
used with the switch.
Apply sealer to the switch threads before installa­
tion. Tightening torque for the switch is 22-34 N#m (192-300 in. lbs.).

BACKUP
LIGHT

SWITCH

J9221-257

Fig.
167
Backup
Light
Switch
Location

Expansion Plug
Replacement
The expansion plugs at the rear of the shift rail
bores (Fig. 168) can be replaced if loose and/or leak­ ing. Replacement procedure is as follows:
(1) Drill 6 mm (1/4 in.) diameter hole in each plug
to be removed.
(2) Pry plug out of cover with tapered punch. (3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel. (4) Apply small bead of sealer to outer edge of each
new plug. Use Mopar silicone adhesive/sealer, or
equivalent.
(5) Position each new plug in bore and tap into
place with hammer and suitable size punch or socket.

Shift
Lever
Replacement
EXPANSION

PLUGS
J9221-258

Fig.
168
Expansion
Plug
Location (1) If transmission is in vehicle, remove shift lever
extension, upper boot and bezel. If transmission is
out of vehicle, temporarily mount cover on gear case.
(2) Remove shift lever lower boot. Unseat boot
from shift tower and slide it off shift lever. (3) Unlock shift lever retainer with two long
screwdrivers for leverage. Press lever retainer down­
ward with screwdrivers. Then turn retainer counter­ clockwise to release retainer from locking pins in shift tower (Fig. 169).
RETAINER

Iff^r
J9221-253

Fig.
169
Unlocking
Shift
Lever
Retainer

•

SHIFT
SPRING
RETAINER
LOWER
BOOT
J9221-259

Fig.
170 Shift
Lever
Components

(5) Lubricate shift lever and retainer contact sur­
faces with petroleum jelly or Castrol Syntorq. (6) If transmission is out of vehicle, temporarily
mount shift cover on gear case.
(7) Position lever assembly in shift tower.
(8) Lock lever retainer in shift tower with two long
screwdrivers. Use screwdrivers to push and turn re­
tainer until it engages both locking pins in tower. (9) Install lower boot on shift lever. Seat boot se­
curely on shift tower.
(10) If transmission is in vehicle, install upper
boot, bezel and shift lever extension.

Shift
Cover
Replacement (1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 171).

Fig.
171 Shift
Cover
Boit
Removal/Installation
(3) Loosen shift cover with pry tool. To avoid dam­
aging cover seal surface, insert pry tool only in slots
provided in cover (Fig. 172). (4) Raise cover enough to disengage it from align­
ment dowels in gear case (Fig. 173).
(5) Raise front of shift cover and lift cover up and
off gear case (Fig. 173). (6) Set cover assembly aside for inspection. If cover
components are damaged, refer to shift cover service information.
NV4500
TRANSMISSION
OVERHAUL
21 - 45

SHIFT

COVER
SLOT

Fig.
172
Loosening
Shift
Cover
SHIFT

Fig.
173 Shift
Cover
Removal/Installation (7) Clean mating surfaces of shift cover and gear
case with wax and grease remover. (8) Apply Mopar Gasket Maker, or Loctite 518 to
sealing surface of shift cover or gear case. Do not
overapply sealer material. Excess can be squeezed
into gear case and could block lubricant feed holes in

time.

(9) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces. (10) Verify that 1-2 and 3-4 synchro sleeves are in
neutral position. Also verify that forks in shift cover are in neutral position. (11) Align and install shift cover (Fig. 173). If
cover will not seat, it is either not aligned on gear
case dowels, or shift forks are not aligned with sleeves and shift lug. (12) Apply Mopar Lock N' Seal or Loctite 242 to
threads of shift cover bolts.
(13) Install and tighten shift cover bolts to 27-31
N*m (216-276 in. lbs.) torque. (14) Install backup light switch in cover. Apply
sealer to switch threads before installation and
tighten switch to 22-34 N*m (193-265 in. lbs.).
(15) Install vent assembly, if removed. Apply an
adhesive/sealer to vent tube to help secure it in
cover.
(4) Lift shift lever upward and remove lever, re­
tainer and spring as assembly (Fig. 170).

21
- 46
G360
MANUAL
TRANSMISSION

G360
MANUAL
TRANSMISSION

INDEX
page
Gear Ratios
46
General
Information
46
Recommended
Lubricant
46

Transmission
Identification
46
Transmission
Installation—2-Wheel
Drive
. 50

GENERAL
INFORMATION
The Getrag G360 transmission
is
used exclusively
with
the
Cummins turbo diesel engine.
It is a
heavy duty, 5-speed, fully synchronized manual transmis­sion
(Fig.
1).
Fifth gear
is an
overdrive range with
a

ratio
of
0.77
to 1.
The G360
is a top
loader style transmission
(Fig.

1).
The
shift lever, shift rails
and
shift forks
are

mounted
in the
transmission shift cover.
The
shift
le­

ver operates
the
shift rails
and
forks directly.

RECOMMENDED
LUBRICANT
Recommended lubricant
for the
Getrag G360 trans­
mission
is SAE
5W-30 engine
oil. The oil
should meet A.P.I, service classifications
SG or
SG-CD.
page
Transmission
Installation—4-Wheel
Drive
.......
52

Transmission Removal—2-Wheel
Drive
........
47

Transmission Removal—4-Wheel
Drive
51

Transmission
Serviceability
47

Lubricant capacity
is 3.3
liters
(3.5
qts.).
The
trans­
mission drain
and
fill plugs
are
both accessible from
the passenger side
of
the
transmission case
(Fig.
2).

TRANSMISSION
IDENTIFICATION
The transmission identification/part number
is im­

printed
on a
metal
tag
attached
to the
passenger side of
the
case
(Fig.
2).

GEAR
RATIOS
G360 gear ratios
are:

First gear
:
5.531:1 Second gear: 3.017:1
Third gear
:
1.60:1
Fourth gear:
1.00:1
Fig.
1
G360 Manual
Transmission

G360
MANUAL TRANSMISSION
21 - 47
on lower boot. Then slide boot upward on lever (Fig.

3).
(3) Remove screws attaching lower boot and plate
assembly to floor pan (Fig. 4).

IDENTIFICATION
PLATE
Fig.
2 G360
identification
Plate
And Drain/Fill
Plug
Locations

Fifth gear : 0.77:1
Reverse : 5.029:1
TRANSMISSION
SERVICEABILITY

The G360 transmission can be serviced when nec­
essary. Replacement parts are available for overhaul. The transmission gear case, rear retainer, counter
gear and countershaft are not serviceable parts. If
these components become damaged to the point of re­
placement, the transmission must be replaced as an assembly.

TRANSMISSION
REMOVAL—2-WHEEL DRIVE
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral and remove
screws attaching shift lever upper boot to metal plate
PLATE

SCREW
(4)
LOWER
.BOOT AND
PLATE

J9121-255
Fig
4 Removing/Installing
Lower
Boot
And
Plate

Attaching
Screws

(4) Remove shift lever extension by either un­
threading, or unbolting it from shift lever (Fig. 5).

LOWER
BOOT AND PLATE BOOT

SCREW
(4)
UPPER

BOOT
LOWER
BOOT AND
PLATE
J9121-254
J9121-256

Fig.
5 Removing/Installing Shift
Lever
Extension
(5) Slide lower boot and plate upward and off shift
lever (Fig. 6).
Fig.
3 Removing/Installing Shift
Lever
Upper
Boot

21
- 48
G360
MANUAL
TRANSMISSION

J9121-257

Fig.
6 Removing/Installing
Lower
Boot
And
Plate
(6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).

Fig.
7 Removing/Installing Shift Tower
Boot

(7) Remove snap ring securing shift lever in shift
tower (Fig. 8).
(8) Remove shift lever (Fig. 10). If lever does not
come out readily, press lever downward and quickly
release it two or three times. Or lightly tap side of lever with plastic mallet to loosen it. Note align- •

Fig.
8
Removing
Shift
Lever
Snap
Ring
ment slots in lever color and pivot ball (Fig. 9).
These slots align with shoulder bolts in shift
tower.
Fig.
9 Removing/Installing Shift
Lever

(9) Raise and support vehicle.
(10) Mark propeller shaft U-joints and axle yokes
for assembly alignment reference (Fig. 10).
(11) Remove propeller shaft. Remove clamp strap
bolts at front of shaft first. Remove center bearing
bracket bolts and support shaft on tool box or stand. Then remove rear clamp strap bolts and remove shaft.
(12) Spread clamps that secure switch wires to
transmission top cover and remove wires from clamps. Move wires aside to protect them and pro­vide working clearance.

•
Fig. 11 Transmission Rear Mount Bolt Locations (14) Support transmission with transmission jack
(Fig. 12). Secure transmission to jack with safety
chains as shown.
(15) On some models it may be necessary to re­
move screws attaching fuel line clamps to driver side
frame rail (Fig. 13). Three clamps must be removed so fuel lines can be moved for access to crossmember
bolts on this side of frame rail.
(16) Remove left and right crossmember-to-frame
braces (Fig. 14) and remove crossmember.
G360 MANUAL
TRANSMISSION
21 - 49

Fig,
12 Transmission Supported On
Jack

Fig. 13 Removing/installing Fuel Line Clamps
SAFETY