M/T - Slips Out of Gear At Low Temperatures

89Chrysler08

Models

1987-89 B/AB, D/AD & N/AN Bodies Equipped With NP2500 Manual 5-Speed Transmission


Subject

Transmission Slips Out Of Gear Only At Low Ambient Temperatures


Index

TRANSMISSION


Date May 8, 1989


No.

21-11-89

(C21-08-9)

P-1742
BODY CODE LEGEND

B/AB - DODGE RAM VAN/WAGON D/AD - DODGE RAM PICKUP N/AN - DODGE DAKOTA/DAKOTA SPORT


This technical service bulletin applies only to NP2500 transmissions with a transmission build date code before 11-24-89.

SYMPTOM/CONDITION


Some vehicles equipped with the NP2500 5-speed manual transmission built before transmission date code 11-24-88 may exhibit a "slips out of gear" condition after the vehicle has been cold soaked at ambient temperature below 32~F (0~C) for several hours. This condition may occur statically with the clutch pedal depressed and/or dynamically when no drive line torque is being transmitted. This condition is the result of the shift lever boot material stiffening at low temperatures and exerting a pulling effort on the shift lever.

Figure 1:

DIAGNOSIS


Verify the transmission build date code. Figure 1
Let the vehicle cold soak in reverse gear for several hours (preferably over night).


IMPORTANT: BEGIN THE DIAGNOSIS WITH THE VEHICLE CAB AT AMBIENT TEMPERATURE.


With the engine off, depress the clutch pedal, shift the transmission into first gear. Check the shift lever for movement into the neutral position. Now shift the transmission into second gear. Check the shift lever for movement into the neutral position. If the shift lever moves into neutral from either first or second gear position start the engine, turn the heater blower to the high blow position and temperature control to the high heat position. After the cab has warmed up repeat the above checks. If the shift lever ceases moving into the neutral from the first and/or second gear position, perform the following repair procedure.


PARTS REQUIRED


3 Springs P/N 53006659
1 Silicone Rubber Adhesive Sealant P/N 4318025

Figure 2:

REPAIR PROCEDURE

This repair involves the removal of the transmission and replacement of the detent springs.

1. Remove the transmission.

2. Remove the four (4) access cover bolts. Carefully pry the access cover up. Figure 2

Figure 3:

3. Remove the three (3) detent springs. Figure 3
4. Clean the access cover and the cover mounting surface on the transmission case. Be sure both surfaces are free of dirt, oil and R.T.V.


NOTE: PREVENT DEBRIS FROM FALLING IN TO THE TRANSMISSION DURING CLEANING OPERATION.


5. Install the three (3) new springs P/N 53006659. New springs are colored yellow.

6. Apply a 1/8 inch bead of silicone rubber adhesive sealant (R.T.V.) P/N 4318025 as shown in Figure 3.

NOTE: DO NOT APPLY AN EXCESSIVE AMOUNT OF R.T.V. TO THE COVER AS THE EXCESS WILL BE SQUEEZED INTO THE DETENT BORES AND THE TRANSMISSION.

7. Install the access cover. Tighten the four (4) cover bolts to 21 ft.lbs (28 N-m) torque.

8. Thoroughly clean the input shaft clutch splines, pilot bushing journal, clutch disc splines and pilot bushing bore. They must be free of any dirt or rust.

9. Apply a light coat of wheel bearing grease P/N 4318064 evenly to the entire length of the exposed input shaft splines. Apply a light coat of multipurpose grease P/N 4318063 to the inside of the pilot bushing bore. Be sure all excessive lubricant is removed.

10. Install the transmission. Check and adjust the transmission lubricant level as required.
POLICY: Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 21-00-06-90 . . . . . . . . . . . . . . . . . . 1.5 Hrs. NP2500-5 Speed Transmission

21-00-06-60 . . . . . . . . . . . . . . . . . . 2.8 Hrs. Optional 4X4 Equipped


FAILURE CODE: 58 - Internal Defect