DODGE TRUCK 1993 Service Repair Manual

21
- 30
NV4500
TRANSMISSION
OVERHAUL

•

SNAP
RING
FIRST

-GEAR

BEARING

MAINSHAFT
SYNCHRO
HUB
J9221-176

Fig.
100 First Gear Bearing
and
Snap
Ring
Installation
(6) Install clutch gear
on
first gear
(Fig. 101). Be

sure clutch gear
is
seated
on
shaft splines. (7) Install first gear snap ring
(Fig. 101). Use

heavy duty snap ring pliers
to
install this snap ring as ring tension
is
considerable.
Do not
overspread
snap ring
and
make sure
it is
fully seated
in

groove. Reverse gear will
not fit
properly
if
snap
ring
is not
fully seated.
FIRST

GEAR
FIRST

GEAR
SNAP
RING

REVERSE
CLUTCH
GEAR

J9221-177
Fig.
101 First Gear,
Clutch
Gear
And
Snap
Ring

Installation

(8) Install stop ring
on
clutch gear
(Fig. 102). Be

sure stop ring
is
fully seated
on
gear taper.
(9) Install reverse gear bearing spacer
on
main-
shaft
(Fig. 103).
Bearing spacer seats against first
gear snap ring. (10) Install reverse gear bearing
on
mainshaft
(Fig.
103).

(11)
If
reverse gear sleeve
and
struts were disas­
sembled
for
service, reassemble sleeve, struts
and

springs
as
follows:
WOOD
BLOCKS
REVERSE
GEAR

STOP
RING

XLUTCH
GEAR
-FIRST
GEAR

\-
-• ~ • - - x J9221-191
i

Fig.
102
Clutch
Gear
Stop
Ring
Installation

REVERSE
GEAR
BEARING
BEARING
SPACER

FIRST

GEAR

J9221-192
Fig.
103
Reverse
Gear Bearing
And
Spacer

Installation

CAUTION:
The
reverse
sleeve
will
fit
either
way
on

the
hub.
This
means
the
sleeve
can be
installed
backwards
if
care
is not
exercised.
Be
sure
the ta­

pered
side
of the
sleeve
faces
rearward
after
instal­
lation.

(a) Position sleeve
on hub so
tapered side
of

sleeve faces rearward. Sleeve will
fit
either
way

but will cause shift problems
if
installed backwards (Fig.
104).
(b) Rotate sleeve
to
align teeth
on
sleeve
and

hub.
Sleeve will slide easily into place
on hub

when properly aligned. (c) Install springs
in
gear
hub (Fig. 104). Use pe­

troleum jelly
to
hold springs
in
place
if
desired.
(d) Compress first spring with flat blade screw­
driver
and
slide strut into position
in hub
slot.
Then work spring into seat
in
strut with small
hooked tool,
or
screwdriver.
(e) Install second
and
third struts
in
same man­
ner
as
described
in
step
(d).
(f) Work sleeve upward
on hub
until struts
are

centered
and
seated
in
sleeve. Sleeve should
be in

neutral position after seating struts.

•

HUB
J922M89
Fig.
104 Reverse Gear Synchro Assembly (12) Install reverse gear and synchro assembly on
mainshaft (Fig. 105). Rotate assembly until stop ring lugs engage in hub slots and gear drops into fully
seated position.

Fig.
105
Reverse
Gear
Installation

(13) Install reverse gear thrust washer pin in main-
shaft (Fig. 106). Use needle nose pliers to install pin.
(14) Install reverse gear thrust washer (Fig. 107).
Be sure locating pin is seated in thrust washer notch.
(15) Install rear bearing on mainshaft. Use In­
staller Tool 6446 to seat bearing on shaft and against
thrust washer (Fig. 108). If bearing is not fully seated on shaft, seat bearing by tapping inner race
with small brass punch and hammer. Bearing inner
race should be flush with shaft.
(16) Turn mainshaft over and place it in horizontal
position on workbench.
(17) Install first speed clutch gear on mainshaft
1-2 synchro hub (Fig. 109). Recessed side of gear
faces front. Be sure gear is seated against snap ring
previously installed on hub.
(18) Install snap ring on mainshaft 1-2 synchro
NV4I00
TRANSMISSION OVERHAUL
21 - 31

Fig.
106 Thrust
Washer
Pin
Installation
Fig.
107
Reverse
Gear Thrust
Washer
Installation

Fig.
108 Installing Mainshaft Rear Bearing
hub to secure clutch gear (Fig. 110). Be sure snap
ring is fully seated in hub groove and against clutch gear. Note that this is second of four snap rings used
to secure synchro components on shaft hub.
(19) Assemble first speed clutch ring and stop ring
(Fig. 111). (20) Install assembled first speed clutch and stop
rings on clutch gear (Fig. 112). Be sure tabs on clutch ring are aligned and seated in first gear

21
- 32
NV4500
TRANSMISSION OVERHAUL

Fig.
109 installing First
Speed
Clutch
Gear

Fig.
110 installing First
Speed
Clutch
Gear
Snap Ring Fig.
111
Assembling
First
Speed
Clutch
And
Stop

Rings

hub.
1-2 synchro hub will not seat properly if clutch ring tabs are misaligned. (21) Support mainshaft in upright position (Fig.

113).
Remaining gears, snap rings and synchro com­
ponents are easier to install with shaft in upright po­ sition. Shaft can be supported in gear case as shown,
or hole can be cut in workbench to support shaft. •

Fig.
112 First
Speed
Clutch
And
Stop Ring
Installation

MAINSHAFT
GEAR
CASE
J9221-222

Fig.
113 Mainshaft
Positioned
For Gear And
Synchro
Installation
(22) If 1-2 synchro hub and sleeve were disassem­
bled for service, reassemble hub, sleeve, struts and springs as follows: (a) Install weights in hub (Fig. 114). Use petro­
leum jelly to hold weights in place if desired. (b) Install weight retainer springs. Flat spring
goes at front side of hub (Fig. 115). Be sure re­
tainer spring ends are securely engaged in weight slots as shown.
(c) Place synchro hub on bench so side of hub
with square spring is facing up (Fig. 116). (d) Align and install sleeve on hub. Be sure ta­
pered side of sleeve faces upward (toward front).
Rotate sleeve until it slides onto hub. Sleeve only

•

NV4500
TRANSMISSION OVERHAUL
21 - 33

HUB
SYNCHRO
Fig.
114 Installing Weights In 1-2
Synchro
Hub
J9221
-207

Fig.
115 Installing Weight Retainer
Springs
In 1-2
Synchro
Hub
fits one way and will easily slide onto hub when
long slot in sleeve, aligns with long shoulder on
hub (Fig. 116).
(e) Place wood blocks under hub that will raise
hub about 3.5 cm (1-3/8 in.) above surface of work­
bench. Then allow sleeve to drop down on hub (Fig.
117).

(f) Install springs and struts in hub (Fig. 117).
Use lots of petroleum jelly to hold them in place.
Then compress struts with your fingers and move sleeve upward until struts are started in sleeve.
Verify that struts are engaged in sleeve before pro­
ceeding.
(g) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated and springs are not displaced during assembly.
Fig.
116 installing 1-2
Synchro Sleeve
On Hub

STRUTS
AND

SPRINGS
(4
EACH)
J9221
-209

Fig.
117 Installing 1-2
Synchro
Struts And
Springs
(23) Install first speed stop ring in 1-2 synchro hub
and sleeve (Fig. 118). Be sure stop ring is fully
seated and engaged in hub and sleeve.
Fig.
118 Installing First
Speed Stop Ring
In
Synchro
Hub

21
- 34
NV4500
TRANSMISSION
OVERHAUL

(24) Install 1-2 synchro assembly and stop ring on
mainshaft. Rotate sleeve to align it with stop ring lugs
if necessary. Then seat assembly on shaft (Fig, 119).
MAINSHAFT

HUB

SYNCHRO

ASSEMBLY
TAPERED SIDE OF

SLEEVE

J9221-211

Fig.
119 1-2
Synchro
Installation
(25) Check position of 1-2 and reverse synchro
sleeves. Be sure tapered side of 1-2 sleeve faces front
and tapered side of reverse sleeve faces rear (Fig.
120).
Also be sure square spring is visible at forward
side of 1-2 synchro hub. Do not skip this check as
transmission will not shift properly if either syn­
chro sleeve is installed backwards. 1-2

SLEEVE
TAPER

TO

FRONT

REVERSE
SLEEVE
TAPER
TO
REAR

J9221-216
Fig.
120 Correct Position Of
Reverse
And 1-2

Synchro
Sleeves

(26) Temporarily remove flat weight spring from
front side of 1-2 synchro hub. Removing spring makes installation of 1-2 hub snap ring easier.
(27) Install snap ring that secures 1-2 synchro on
mainshaft hub (Fig. 121). Be sure snap ring is fully seated in ring groove in mainshaft hub. If snap ring
will not seat in groove, round weight spring at
rear of 1-2 synchro hub is probably not seated in
recess at front of first speed clutch gear. Or first speed clutch gear is slightly misaligned. Realign
as needed to fully seat snap ring.
SYNCHRO

SNAP
RING

SYNCHRO

ASSEMBLY

J9221-212

Fig.
121 Installing 1-2
Synchro
Snap
Ring
(28) Reinstall flat weight spring in 1-2 synchro
hub (Fig. 122). Be sure spring ends are securely en­
gaged in weight slots.
FLAT

WEIGHT
SPRING
1-2

SYNCHRO
HUB
fll^ \\V ^221-213

Fig.
122 Reinstalling
Flat
Weight
Spring

(29) Assemble second speed clutch gear, clutch
ring and stop ring (Fig. 123).

STOP
RING
CLUTCH
RING

CLUTCH
GEAR
J9221-200

Fig.
123
Assembling
Second
Speed
Clutch
Gear,
Clutch
Ring
And
Stop
Ring

NV450Q
TRANSMISSION
OVERHAUL
21 - 35
(30) Install assembled second speed clutch gear
and rings on mainshaft and in 1-2 synchro hub (Fig.
124).
Fig.
124
Second
Speed
Clutch
Gear,
Clutch
Ring

And
Stop
Ring
Installation (31) Install snap ring that secures second speed
clutch gear on mainshaft (Fig. 125). Use narrow
blade screwdriver to work snap ring into hub groove as shown. Be sure snap ring is fully engaged in
mainshaft groove before proceeding. If snap
ring will not fit in groove, clutch gear is slightly
misaligned. Or, flat weight spring at front of 1-2 synchro hub is probably not seated in recess in
front of second speed clutch gear.

Fig.
125 Installing
Second
Speed
Clutch
Gear
Snap
Ring

(32) Install second gear bearing on mainshaft (Fig.

126).

(33) Install second gear on mainshaft and bearing.
Rotate gear until tabs of second speed clutch ring are
fully seated in tab slots in gear (Fig. 127).
(34) Install thrust washer pin in shaft (Fig. 128).
Use needle nose pliers to insert pin in shaft hole.
Fig.
126
Second
Gear Bearing Installation
1
SECOND
GEAR

Fig.
127
Second
Gear Installation

Fig.
128 Thrust
Washer
Pin Installation

21
- 36
NV4500
TRANSMISSION
OVERHAUL
-

SECOND SECOND

J9221-224

Fig.
129
Second
Gear Thrust
Washer
installation

(36) Install second gear thrust washer snap ring
(Fig. 130). Be sure snap ring is fully seated in main-
shaft groove. (37) Install third gear bearing spacer on shaft and
seat it against thrust washer snap ring (Fig. 130).
THRUST

WASHER

SNAP
RING

HIRD
GEAR
BEARING
SPACER
J922M22

Fig.
130 Installing
Snap
Ring
And Third Gear

Bearing
Spacer
(38) Install third gear bearings on mainshaft (Fig.

131).
Upper bearing should be flush with mainshaft

hub.
If upper bearing is not flush with hub, ei­ ther bearing spacer or snap ring was not in­stalled. Check and correct if necessary.
(39) Install third gear over bearings and on main-
shaft (Fig. 132). (40) Install synchro stop ring on third gear (Fig.

133).
Be sure stop ring is fully seated on gear taper. (41) If 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align and install synchro sleeve on hub (Fig.

134).
Front side of hub has a narrow groove
machined in it.
Fig.
131 Third Gear Bearing
Installation

Fig.
132 Third Gear
Installation
SYNCHRO
THIRD

Fig.
133 Third Gear
Stop
Ring
Installation
(b) Insert all three synchro struts in slots ma­
chined in sleeve and hub (Fig. 134). (c) Install and seat synchro springs (Fig. 134).
Use flat blade or phillips screwdriver to compress springs and seat them in struts and hub as shown.
(42) Remove mainshaft and geartrain from gear
case or from workbench.
(43) Start 3-4 synchro assembly on mainshaft. Tap
assembly onto shaft splines until hub is about 3 mm (1/8 in.) away from third speed stop ring. Then align
stop ring with synchro sleeve and hub and seat syn­
chro assembly with Tool C-4040 (Fig. 135).
(44) Verify that 3-4 synchro hub is fully seated on
shaft. Approximately 3 mm (1/8 in.) of shaft spline should be visible. If hub is not seated, stop ring lugs
are misaligned. Rotate ring until lugs are fully en­
gaged in 3-4 hub slots.
(35) Install second gear thrust washer. Be sure
washer is seated on gear and pin (Fig. 129).

•

IV4500
TRANSMISSION OVERHAUL
21 - 37
Fig
134 3-4
Synchro
Assembly

Fig.
135 Seating 3-4
Synchro
Assembly
On Mainshaft
(45) Install fourth speed stop ring in 3-4 synchro
sleeve (Fig. 136).
Fig.
136 Fourth
Speed
Stop
Ring
Installation

(46) Install fourth speed clutch gear in stop ring
(Fig. 137).
MAINSHAFT AND GEARTRAIN INSTALLATION (1) Position gear case so case opening is facing up
(Fig. 138).
(2) Grip mainshaft at pilot bearing hub and just
behind rear bearing. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
Fig.
137 Fourth
Speed
Clutch
Gear
Installation

(3) Continue holding front of shaft but switch grip
at rear to shaft output splines. Lift mainshaft assem­
bly slightly, align gears and seat assembly in case. Be sure fourth speed clutch gear and stop ring were not displaced during installation (Fig. 138).
MAINSHAFT

Fig.
138 Mainshaft And
Geartrain
Installed In
Case
(4) Install drive gear thrust bearing on mainshaft
(Fig. 139). Use plenty of petroleum jelly to hold bear­
ing in place.
(5) Check alignment and mesh of mainshaft gears.
If gears are not aligned, roll case on side and realign
shaft and gears in case.
Fig.
139 Drive Gear Thrust Bearing
Installation

21
- 38
NV45U0
TRANSMISSION OVERHAUL

DRIVE GEAR AND RETAINER INSTALLATION
(1) Install bearing on drive gear with Installer
Tool 6448 (Fig. 140).

SPECIAL
-TOOL
6448

BEARING DRIVE GEAR

J9221-204
Fig.
140 installing Front Bearing On Drive Gear
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear
rearward until mainshaft hub is fully seated in pilot
bearing.
(4) Install bearing cup in front retainer with
Driver Handle C-4171 and Installer C-4308 (Fig.
141).
SPECIAL
TOOL

C-4308
SPECIAL

TOOL

C-4171
WOOD

BLOCKS
RETAINER

J9221-203
Fig.
141 Installing Front Bearing Cup In Retainer
(5) Install new oil seal in front bearing retainer
with Tool C-4595 or 6052 (Fig. 142). Use one or two
wood blocks to support retainer as shown. Lubricate seal lip with petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover. (7) Apply Mopar Gasket Maker to flange surface of
front bearing retainer (Fig. 143). (8) Install front bearing retainer over drive gear
and start it into case.
WOOD
BLOCK
SPECIAL
TOOL

6052

RETAINER

J9221-202

Fig.
142 Installing Bearing Retainer Oil
Seal
(9) Start front bearing retainer in gear case. Ver­
ify that retainer lube channel is at top-center (12
O'clock)
position (Fig. 143). Adjust retainer posi­
tion before proceeding, if necessary.
LUBE

CHANNEL

(INSTALL
AT

12
O'CLOCK
POSITION)

APPLY

GASKET
MAKER
HERE
FRONT

RETAINER

J9221-231
Fig.
143 Location Of Front Retainer
Lube
Channel

(10) Align front bearing retainer bolt holes and tap
retainer into place with plastic mallet. Install and
tighten retainer bolts to 30 N-m (265 in. lbs.) torque (Fig. 144).
FRONT
BEARING

RETAINER
9 J9221-103

Fig.
144 Installing Front Bearing Retainer

NV4500
TRANSMISSION
OVERHAUL
21 - 39

MAINSHAFT
END
PLAY
ADJUSTMENT

(1) Install mainshaft rear bearing
cup in
case
and

over bearing.
Tap
bearing
cup
into place with plastic
mallet. (2) Install rear bearing plate
to
hold mainshaft
and rear bearing
in
position (Fig. 145).
Do not
install
any
end
play shims
at
this time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case
in
upright position
on
bench.
Either
cut
hole
in
bench
to
accept drive gear
and

front retainer,
or use
C-clamps
to
secure transmis­ sion
on
bench.
Do not
leave transmission unsup­
ported.
(5) Mount dial indicator
on
rear
of
gear case
and

position indicator plunger against inner race
of
rear
bearing (Fig.
145).

(6) Move mainshaft forward
to
remove
all
play.
Then zero dial indicator.
(7) Move mainshaft upward
and
observe dial indi­
cator reading. Move mainshaft with
pry
tool posi­
tioned between drive gear
and
case. (8)
End
play should
be
0.051-0.15
mm
(0.002-0.006

in.).
Select
fit
shims
are
available
to
adjust
end
play
if necessary.
DIAL
INDICATOR AND
BASE REAR
BEARING
(j
POSITION
J INDICATOR

(J
PLUNGER
.

L/L-ON
BEARING-
(/ INNER RACE
J9221-232

Fig.
145
Checking
Mainshaft End Play
(9)
If end
play adjustment
is
required, remove
bearing plate
and
install necessary shim. (10) Reinstall rear bearing plate
(Fig. 146).

Tighten rear bearing plate bolts
to 23 N*m (200 in.
lbs.) torque.
Be
sure
oil
hole
in
bearing plate
is at

top
as
shown.

MAINSHAFT
FIFTH
GEAR
INSTALLATION
(1) Install mainshaft fifth gear.
Use
Installer Tool
6446
to
seat gear
on
shaft (Fig. 147). Gear
is
seated
when
it
contacts rear bearing.
(2) Install fifth gear
nut
washer (Fig. 148). Coned
side
of
washer faces
end of
shaft.
(3) Apply
3-4
drops Mopar Lock
N'
Seal,
or
Loctite
242
to nut
threads
on
mainshaft. BEARING
PLATE
OIL HOLE
(AT
TOP) MAINSHAFT
REAR
BEARING PLATE

J9221-233

Fig.
146 Rear Bearing
Plate
Installation
MAINSHAFT FIFTH
GEAR SPECIAL
TOOL
6446
J9221-220

Fig.
147 Installing Mainshaft
Fifth
Gear
(4) Install fifth gear
nut on
mainshaft (Fig.
148).

FIFTH
GEAR NUT
WASHER
'(CONED)
FIFTH
GEAR NUT

J9221-93

Fig.
148 Installing
Fifth
Gear Nut And
Washer

(5) Tighten fifth gear
nut as
much
as
possible with
Nut Wrench
6443,
long handle ratchet, breaker
bar
and Socket Wrench 6441
or
6442 (Fig.
149).