boot DODGE TRUCK 1993 Service Owner's Guide

1
.

NW4500
MANUAL
TRANSMISSION 21 - 5 making transmission removal/installation easier.
Cylinder does not have to be removed completely. (28) Remove bolts attaching transmission to clutch
housing.
(29) Move transmission rearward until drive pin­
ion clears clutch disc and release bearing. (30) Lower transmission and remove it from under
vehicle.
(31) If transmission will be overhauled, thoroughly
clean transmission exterior with solvent or steam
gun.
TRANSMISSION INSTALLATION-4-WHEEL DRIVE (1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com­
ponents: • drive gear splines and pilot bearing hub • release bearing slide surface of front retainer
• pilot bearing
• release bearing bore
• release fork
• release fork ball stud
• propeller shaft slip yoke (2) Fill transmission with recommended lubricant.
Correct level is to bottom edge of fill plug hole. (3) Mount transmission on jack and position trans­
mission under vehicle. Secure transmission to jack
with safety chains. (4) Raise transmission until drive gear is centered
in release bearing and clutch disc hub. (5) Move transmission forward and start drive gear
in release bearing and clutch disc. (6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after drive gear has entered clutch disc. (7) Install and tighten transmission-to-clutch hous­
ing bolts to 108 N*m (80 ft. lbs.) torque. (8) Connect speed sensor and backup light switch

wires.
(9) Position transmission harness wires in clips on
shift cover. (10) Tighten slave cylinder attaching nuts and in­
stall slave cylinder shield, if equipped.
(11) Install transmission mount on transmission or
rear crossmember. (12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Install transfer case on transmission jack. Se­
cure transfer case to jack with safety chains. (15) Install new gasket on transmission adapter, or
coat adapter sealing surface with Mopar Gasket
Maker, or silicone adhesive sealer.
(16) Raise jack and align transfer case input gear
with transmission mainshaft.
(17) Move transfer case forward and seat it on
adapter.
(18) Install and tighten transfer case attaching
nuts to 47 N«m (35 ft. lbs.) torque.
(19) Connect transfer case shift lever to range le­
ver on transfer case. (20) Align and connect propeller shafts. Tighten
U-joint clamp strap bolts to 19 N*m (170 in. lbs.)
torque.
(21) Check lubricant levels in transmission and
transfer case. Add lubricant if necessary.
(22) Install transfer case skid plate and crossmem­
ber. Tighten attaching bolts/nuts to 41 N»m (30 ft. lbs.) torque.
(23) Install exhaust system components.
(24) Lower vehicle.
(25) Install transmission shift lever, boot and be­

zel.

(26) Connect battery negative cable.

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).

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.

•
• release fork ball stud
• propeller shaft slip yoke

APPLY
LIGHT
COAT
OF

HI-TEMP
GREASE
TO
THESE

SURFACES
BEFORE
INSTALLATION
J9106-15

Fig.
18 input Shaft Lubrication
Points
(Typical)
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re­ lease bearing and clutch disc hub. Rotate output
shaft with socket or yoke to align input shaft and
clutch disc splines if necessary.
(4) Move transmission forward and seat transmis­
sion against housing. (5) Install and tighten transmission mounting
bolts to 68 N-m (50 ft-lbs). (6) Install rear crossmember and crossmember
brackets. Start all crossmember bolts/nuts before
tightening to final torque of 68 N»m (50 ft-lbs). (7) Remove transmission jack.
(8) Install screws that attach fuel line clamps to
driver side frame rail. (9) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (10) Install clutch slave cylinder shield.
(11) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(12) Align and install propeller shaft. Support
shaft on box or stand. Install shaft front U-joint first.
Next, secure center bearing bracket to frame bracket.
Then install shaft rear U-joint in axle yoke. Final- tighten U-joint clamp bolts to 19 N@m (14 ft-lbs) and center bearing bracket bolts to 68 N»m (50 ft-lbs). (13) Lower vehicle.
(14) Lubricate shift lever ball and collar with Mo­
par all purpose grease. (15) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (16) Press shift lever and collar downward and in­
stall shift lever snap ring. (17) Tighten shift lever alignment bolts com­
pletely. (18) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (19) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large G360
MANUAL TRANSMISSION
21 - 51

SKID

PLATE
J9121-525

Fig.
19 Transfer
Case
Skid
Plate
Mounting
notch is forward then install lower boot attaching
screws. (20) Thread or bolt shift lever extension to shift le­
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws.
(21) Install shift knob on extension (if removed). (22) Connect battery negative cable.

TRANSMISSION REMOVAL—4-WHEEL DRIVE
(1) Disconnect battery negative cable.
(2) Remove screws attaching shift lever upper boot
to metal plate 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). (4) Remove shift lever extension by unthreading it
from shift lever (Fig. 5). (5) Slide lower boot and plate upward and off shift
lever (Fig. 6). (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).

(7)
Remove snap ring securing shift lever in shift
tower (Fig. 8). (8) Remove shift lever (Fig. 9). If lever does not
come out readily, press lever downward and quickly
release it two or three times. Pressure from spring under lever should push it out of housing. Note alignment slots in lever cover and pivot ball
(Fig. 9). These slots align with shoulder bolts in
shift tower.
(9) Raise and support vehicle.
(10) Mark front and rear propeller shafts for in­
stallation reference (Fig. 10). Then disconnect and re­
move both shafts. (11) Remove transfer case skid plate and cross-
member (Fig. 19).

21 - 52 G360
MANUAL
TRANSMISSION

• (12) Disconnect wires at vehicle speed sensor and
backup light switch.
(13) Disconnect transfer case shift lever from lever
on transfer case.
(14) Temporarily support transmission with adjust­
able jack stand. Then support transfer case with
transmission jack.
(15) Remove nuts attaching transfer case to trans­
mission adapter and move transfer case away from
transmission rear retainer.
(16) Lower transfer case and move it from under
vehicle. Remove transfer case from transmission jack and place transfer case on workbench.
(17) Support transmission with transmission jack.
Secure transmission to jack with safety chains. Then
remove jack stand previously used to support trans­
mission.
(18) Spread clamps that secure switch wires to
transmission top cover and remove wires from clamps. Move wires aside to protect them and pro­
vide working clearance.
(19) Remove bolts attaching transmission rear
mount to crossmember.
(20) On some models, it is necessary to remove
screws attaching fuel line clamps to driver side
frame rail. Three clamps must be removed to so fuel lines can be moved for access to crossmember bolts at
this side of frame rail.
(21) Remove left and right crossmember-to-frame
braces and remove crossmember.
(22) Remove clutch slave cylinder shield.
(23) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever (Fig.

20).
This reduces pressure on lever and release bear­
ing making transmission removal/installation easier. Cylinder does not have to be removed completely.
(24) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission slightly to help free input shaft from clutch disc and
release bearing.
(25) Support engine with wood block and another
adjustable jack stand.

TRANSMISSION
INSTALLATION—4-WHEEL
DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains.
(2) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of input shaft (Fig. 20) and following components:

CAUTION:
Do not use
excessive
amounts
of
grease.

This
practice
could
result in contamination of the

clutch
disc.

• input shaft splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bushing
• release bearing bore
• release fork
• release fork ball stud • propeller shaft slip yoke
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re­ lease bearing and hub of clutch disc. (4) Rotate output shaft with socket or yoke to align
input shaft and clutch disc splines. If input shaft will
not rotate enough in neutral to align splines, it will
be necessary to shift transmission into third or fourth gear with screwdriver. (5) Seat transmission against clutch housing and
align bolt holes in transmission and housing. (6) Install and tighten transmission-to-clutch hous­
ing bolts to 68 N-m (50 ft. lbs.). (7) Install rear crossmember and mount. Start all
crossmember bolts/nuts then tighten them to 68 N*m (50 ft. lbs.) torque. (8) Remove transmission jack.
(9) Install screws that attach fuel line clamps to
driver side frame rail. (10) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (11) Install clutch slave cylinder shield.
(12) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(13) Install gasket and transfer case on transmis­
sion rear retainer. Tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque. (14) Check transmission and transfer case lubri­
cant levels. Add lubricant if necessary and install fill

plugs.

(15) Connect transfer case shift lever to lever on
transfer case.
(16) Align and install propeller shafts. Tighten
U-joint clamp bolts to 19 N-m (14 ft. lbs.). (17) Install skid plate and crossmember. Tighten
skid plate and crossmember bolts/nuts to 41 N—m
(30 ft. lbs.) torque.
(18) Lower vehicle.
(19) Shift transmission into neutral if necessary.
(20) Lubricate shift lever ball and collar with Mo­
par all purpose grease. (21) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (22) Press shift lever and collar downward and in­
stall shift lever snap ring. (23) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (24) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large
notch is forward then install lower boot attaching screws. (25) Thread or bolt shift lever extension to shift le­
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws. (26) Install shift knob on extension (if removed).
(27) Connect battery negative cable.

•
G360
TRANSMISSION
OVERHAUL
21 - 63 The retainer seals have a small spring around the in­
ner part of the seal. Be sure each seal is installed
with this spring facing the case interior.
The snap rings should all be replaced. Eeusing
snap rings is not recommended.

Shift
Cover
Inspect the shift cover components (Fig. 33). The
only serviceable shift cover components are the shift
lever, lever retainer ring, snap ring, boot and clamp, and backup light switch.
If any of the shift forks, shift rails, or shift rail de­
tent parts are worn, or damaged, replace the shift cover assembly.
COVER 1-2 3-4

SHIFT

RAILS
J9321-310

Fig.
33 Shift
Cover
Assembly

TRANSMISSION
ASSEMBLY
AND
ADJUSTMENT

Assembly
Information
The only gasket in current G360 transmissions is
the shift cover gasket. All other sealing surfaces are
to be sealed with a coating of Mopar Gasket Maker, or Loctite 518.
Prior production G360 transmissions with the
early style gear case, were not equipped with a shift cover gasket. It is recommended that a gas­
ket be used on these transmissions during over­
haul or whenever the shift cover is removed during service. A gasket is available separately
or as part of the basic overhaul kit.
Apply Mopar Lock N' Seal, or Loctite 242 to bolt
threads before installation. These products will en­ sure proper fastener retention and sealing.
Lubricate the transmission components with Mopar
5W-30 engine oil or equivalent, during assembly. Pe­ troleum jelly can be used to hold parts in place and
prelubricate bearings and seal lips.
Do not use chassis grease, or similar products
on any component during assembly. Heavy lu­
bricating grease will plug the transmission oil
passages resulting in failure. Preload adjustments are required for the output
shaft and countershaft bearings. Preload is accom­
plished by the use of select fit shims. An accurate
vernier style depth gauge, depth micrometer, or dial indicator and suitable mounting stand are required
for measurement and adjustment. The procedure is described in the Bearing Preload Adjustment section.
ASSEMBLING OUTPUT SHAFT AND
GEARTRAIN

(1) Lubricate mainshaft, gears and synchro compo­
nents with Mopar 5W-30 engine oil. (2) Install blocker rings on first and second gears
as follows:
(a) Start roll pins into blocker rings and gears
with hammer (Fig. 34). (b) Seat roll pins with pin punch (Fig. 35). Be
sure roll pins are seated flush with surface of each
blocker ring. Do not drive pins below surface of
rings.

Fig.
34 Starting
Roll
Pins
In
First/Second
Gear
Blocker
Rings

(3) Install bearing in second gear and install sec­
ond gear on output shaft (Fig. 36).
(4) Install second gear thrust washer on output
shaft (Fig. 37). Washer is tight fit on shaft. Heat
washer in oven or use suitable tool to seat
washer on shaft.If washer is heated to ease instal­
lation, heat washer for no more than 5 minutes at

200°F.

21 - 344
NP205
TRANSFER
CASE

• (a) Raise vehicle and disconnect both propeller
shafts at the transfer case.
(b) Position supports under the transmission.
(c) Remove the bolts/nuts attaching the transfer
case adapter to the crossmember and transmission. (d) Support the transfer case with a transmission
jack and slide the transfer case and adapter clear of the transmission output shaft.
(e) Have helper start engine and shift transmis­
sion into gear. If transmission output shaft rotates,
problem is with transfer case. If transmission shaft
does not rotate, problem is with transmission or re­ lated component.

SHIFT
LINKAGE
ADJUSTMENT
(1) Shift transfer case into neutral.

(2)
Remove screws attaching shift lever boot and
seal to floor pan (Fig. 2). (3) Slide shift lever boot and seal upward for vi­
sual access to shift gate. Verify that lever is in Neu­
tral position. (4) Loosen bolts" attaching shift lever bracket to
adapter (Fig. 3).
Fig.
2 Shift
Lever
Boot
And
Seal

Fig.
3 NP205 Shift
Linkage

21 - 354 NP241
TRANSFER
CASE

•
SHIFT
LINKAGE
ADJUSTMENT

(1) Remove screws attaching shift lever boot and
seal to floorpan (Fig. 7). Then move boot and seal aside for visual access to shift gate. (2) Move shift lever into 4H position. Be sure lever
is against 4H position in gate. (3) Raise vehicle.
(4) Loosen lock bolt in shift rod adjusting swivel
(Fig. 8). (5) Check shift rod fit in swivel. Be sure rod does
not bind in swivel. (6) Verify that transfer case range lever is in 4H
position (vertical). Move lever if necessary. (7) Tighten shift rod lock bolt to (90 in. lbs.)
torque. (8) Lower vehicle.
(9) Check shift linkage operation.
Fig.
7 Shift
Lever
Boot
And
Seal