Internal Components
ASSEMBLYGaskets are not used in the NV3500 transmission. Sealers are used at all case joints. The recommended sealer is Mopar silicone sealer, or equivalent. Apply these products as indicated in the assembly procedures.
NOTE: It is very important that the transmission shift components be in Neutral position during assembly. This is necessary to prevent damaging synchro and shift components when the housings are installed.
The 3-4, 1-2 and fifth-reverse synchro hub snap rings can be fitted selectively. New snap rings are available in 0.05 mm (0.0019 inch) thickness increments. Use the thickest snap ring that will fit in each snap ring groove.
SYNCHRO COMPONENT ASSEMBLY
The easiest method of assembling each synchro is to install the springs, struts and detent balls one at a time as follows:
1. Slide the sleeve part way onto the hub. Leave enough room to install the spring in the hub and the strut in the hub groove.
2. Install the first spring in the hub. Then install a strut over the spring. Be sure the spring is seated in the spring bore in the strut.
3. Slide the sleeve onto the hub just far enough to hold the first strut and spring in place.
4. Place the detent ball in the top of the strut. Then carefully work the sleeve over the ball to hold it in place. A small flat blade screwdriver can be used to press the ball into place while moving the sleeve over it.
5. Repeat the procedure for the remaining springs, struts and balls. Tape, or a rubber band can be used to temporarily secure each strut and ball as they are installed.
Fig. 51:
6. Verify synchro assembly. Be sure the three springs, struts and detent balls are all in place (Fig. 51).
OUTPUT SHAFT ASSEMBLY
1. Lubricate shaft, gears and bearings with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.
2. Check bearing surfaces of output shaft for nicks or scratches. Smooth surfaces with 320/400 grit emery cloth if necessary. Apply oil to emery cloth and shaft surface before polishing.
3. Inspect and replace any synchro ring that exhibits wear or damage. Completely immerse each synchro ring in lubricant before installation.
Fig. 52:
4. Lubricate and install reverse gear needle bearing on shaft (Fig. 52). Slide bearing up against shoulder on output shaft.
Fig. 53:
5. Install reverse gear over needle bearing (Fig. 53).
Fig. 54:
6. Install solid brass synchro ring on reverse gear (Fig. 54).
7. Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.
CAUTION: The fifth-reverse synchro hub and sleeve can be installed backwards if care is not exercised. One side of the hub has shoulders around the hub bore. Make sure this side of the hub is facing the front of the shaft. In addition, one side of the sleeve is tapered. Be sure the sleeve is installed so the tapered side will be facing the front of the shaft.
Fig. 55:
8. Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover 6310-1 (Fig. 55).
Fig. 56:
9. Install new fifth-reverse hub snap ring (Fig. 56) as follows:
a. Snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to 0.086 inch).
b. Install thickest snap ring that will fit in shaft groove.
c. Verify that snap ring is completely seated in groove before proceeding.
Fig. 57:
10. Install fifth gear synchro ring in synchro hub and sleeve (Fig. 57).
Fig. 58:
11. Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft (Fig. 58). Be sure bearing is properly seated after installation.
Fig. 59:
12. Install fifth gear on shaft and onto bearing (Fig. 59).
Fig. 60:
13. Invert output shaft and set the shaft in Remover 6310-1 so that fifth gear is seated on the tool (Fig. 60).
14. Install first gear bearing on output shaft (Fig. 60). Be sure bearing is seated on shaft shoulder and is properly joined.
15. Install the first gear inner blocker ring onto first gear.
Fig. 61:
16. Install first gear on shaft and over bearing (Fig. 61).
17. Install the first gear friction cone over the inner blocker ring.
Fig. 62:
18. Install first gear synchro/outer blocker ring (Fig. 62) over the first gear friction cone.
19. Assemble 1-2 synchro hub sleeve, springs, struts and detent balls.
CAUTION: The 1-2 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the synchro sleeve is marked First Gear Side. Be sure this side of the sleeve will face first gear after installation.
Fig. 63:
20. Start 1-2 synchro assembly on shaft by hand (Fig. 63). Be sure synchro sleeve is properly positioned. Side marked first side must be facing first gear.
Fig. 64:
21. Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 64).
CAUTION: Take time to align the synchro ring and sleeve as hub the is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.
Fig. 65:
22. Install new 1-2 synchro hub snap ring (Fig. 65) as follows:
a. Snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 inch).
b. Install thickest snap ring that will fit in shaft groove.
c. Verify that snap ring is completely seated in groove before proceeding.
Fig. 66:
23. Install second gear synchro/outer blocker ring in 1-2 synchro hub and sleeve (Fig. 66). Be sure synchro ring is properly seated in sleeve.
24. Install the second gear friction cone into the second gear synchro/outer blocker ring.
25. Install the second gear inner blocker ring into the friction cone.
Fig. 67:
26. Install second gear needle bearing on shaft (Fig. 67).
Fig. 68:
27. Install second gear onto shaft and bearing (Fig. 68). Make sure that second gear is fully seated on synchro components.
Fig. 69:
28. Install two-piece thrust washer (Fig. 69). Be sure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. Also, ensure that the I.D. grooves and markings noted during removal are facing the correct direction. The diamond shaped marks on the face of the washer must face the front of the shaft.
Fig. 70:
29. Start retaining ring around two-piece thrust washer (Fig. 70). Make sure that the locating dimple is between the thrust washer halves.
Fig. 71:
30. Seat thrust washer retaining ring with plastic mallet (Fig. 71).
Fig. 72:
31. Install third gear needle bearing on shaft (Fig. 72).
Fig. 73:
32. Install third gear on shaft and bearing (Fig. 73).
Fig. 74:
33. Install third gear synchro ring on third gear (Fig. 74).
34. Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls.
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has grooves in it. Be sure this side of sleeve is also facing the front of the shaft.
Fig. 75:
35. Start 3-4 synchro hub on output shaft splines by hand (Fig. 75).
Fig. 76:
36. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 76). Make sure that the tool presses on hub as close to output shaft as possible but does not contact the shaft splines.
Fig. 77:
37. Install 3-4 synchro, hub snap ring (Fig. 77) as follows:
a. Snap rings are available in thicknesses from 2.00 mm to 2.30 mm (0.078 to 0.090 inch).
b. Install thickest snap ring that will fit in shaft groove. Use heavy duty snap ring pliers to install new ring.
c. Verify that snap ring is completely seated in groove before proceeding.
38. Install output shaft bearing.
Fig. 78:
39. Install output shaft bearing snap ring (Fig. 78). Use heavy duty snap ring pliers and spread snap ring only enough to install it. Be sure snap ring is completely seated in shaft groove before proceeding.
Fig. 79:
40. Verify correct position of synchro sleeves before proceeding with assembly operations (Fig. 79). Grooved side of 3-4 sleeve should be facing forward. First gear side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.
REVERSE IDLER ASSEMBLY
1. Lubricate idler components with gear lube.
Fig. 80:
2. Slide idler gear bearing on shaft (Fig. 80). Bearing fits either way on shaft.
3. Slide gear onto shaft. Side of gear with recess goes to rear (Fig. 80).
4. Place first lock ball in dimple at rear end of idler shaft (Fig. 80). Petroleum jelly can be used to hold ball in place if desired.
Fig. 81:
5. Slide thrust rear thrust washer onto shaft and over lock ball (Fig. 81).
6. Install snap ring in groove at rear of shaft (Fig. 81).
7. Install lock ball in dimple at front of shaft. Hold ball in place with petroleum jelly if desired.
Fig. 82:
8. Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 82).
9. Install wave washer, flat washer and remaining snap ring on idler shaft (Fig. 82). Be sure snap ring is fully seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS
1. Inspect shift shaft bushing and bearing for damage.
2. If necessary, the shift shaft bushing can be replaced as follows:
a. Locate a bolt that will thread into the bushing without great effort.
b. Thread the bolt into the bushing, allowing the bolt to make its own threads in the bushing.
c. Attach a slide hammer or suitable puller to the bolt and remove bushing.
d. Use the short end of Installer 8119 to install the new bushing.
e. The bushing is correctly installed if the bushing is flush with the transmission case.
3. If necessary, the shift shaft bearing can be replaced as follows:
a. Locate a bolt that will thread into the bearing without great effort.
b. Thread the bolt into the bearing as much as possible.
c. Attach a slide hammer or suitable puller to the bolt and remove the bearing.
d. Use the short end of Installer 8119 to install the new bearing.
e. The bearing is correctly installed if the bearing is flush with the transmission case.
4. Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to a specific depth. The space between the two bushings when correctly installed contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted.
5. If necessary, the detent plunger bushings can be replaced as follows:
a. Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore.
b. Remove the bushings from the shift shaft bore.
c. Install a new detent plunger bushing on the long end of Installer 8118.
d. Start the bushing in the detent plunger bore in the case.
e. Drive the bushing into the bore until the tool contacts the transmission case.
f. Install a new detent plunger bushing on the short end of Installer 8118.
g. Start the bushing in the detent plunger bore in the case.
h. Drive the bushing into the bore until the tool contacts the transmission case.
GEARTRAIN ASSEMBLY IN FIXTURE:
Fig. 83:
1. Install Adapter 6747-1A on input shaft hub of fixture tool (Fig. 83). Then install Adapter 6747-2A on front bearing hub of countershaft. Adapter 6747-2A has a raised shoulder on one side. Be sure the shoulder is seated against the countershaft.
Fig. 84:
2. Install input shaft in fixture tool. Make sure Adapter Tool 6747-1A is positioned under shaft as shown (Fig. 84).
3. Install pilot bearing in input shaft (Fig. 84).
NOTE: The pilot bearing can be installed backwards if care is not exercised. Be sure the large diameter side of the roller retainer faces the output shaft and the small diameter side faces the input shaft.
Fig. 85:
4. Install fourth gear synchro ring on input shaft (Fig. 85).
Fig. 86:
5. Adjust height of idler gear pedestal on assembly fixture (Fig. 86). Start with a basic height of 18.4 cm (7-1/4 inch). Final adjustment can be made after gear is positioned on pedestal.
Fig. 87:
6. Install assembled output shaft and geartrain in input shaft (Fig. 87). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
7. Install Adapter 6747-2A on front bearing hub of countershaft, if not previously done. The adapter has a shoulder on one side. The shoulder goes toward the countershaft.
Fig. 88:
8. Slide countershaft (and adapter) into fixture slot. Verify that countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding (Fig. 88).
9. Check alignment of countershaft and output shaft gear teeth. Note that gears may not align perfectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 inch) will probably exist. This difference will not interfere with assembly. However, if the difference is greater than this, the countershaft adapter tool is probably upside down. Remove countershaft, reverse adapter tool, reinstall countershaft and check alignment again.
Fig. 89:
10. Position reverse idler in support cup of assembly fixture (Fig. 89). Be sure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary. Also be sure that short end of idler shaft is facing up as shown.
Fig. 90:
11. On 2-wheel drive transmission, thread one Pilot Stud 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (Fig. 90).
Fig. 91:
12. Assemble 1-2 and fifth reverse-shift forks (Fig. 91). Arm of fifth-reverse fork goes through slot in 1-2 fork.
Fig. 92:
13. Install assembled shift forks in synchro sleeves (Fig. 92). Be sure forks are properly seated in sleeves.
REAR HOUSING INSTALLATION
Fig. 93:
1. Drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface (Fig. 93).
2. Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race.
Fig. 94:
3. Install countershaft rear bearing in bearing race (Fig. 94).
Fig. 95:
CAUTION: The countershaft bearings can be installed backwards if care is not exercised. Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 95).
4. Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed.
5. Apply light coat of petroleum jelly to shift shaft bushing/bearing in rear housing (Fig. 95).
6. Reach into countershaft rear bearing with finger, and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place. This avoids having rollers becoming displaced during housing installation. This will result in misalignment between bearing and countershaft bearing hub.
Fig. 96:
7. Install rear housing onto geartrain (Fig. 96). Be sure bearing retainer pilot stud is in correct bolt hole in housing. Also be sure countershaft and output shaft bearings are aligned in housing and on countershaft. It may be necessary to lift upward on countershaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages the housing.
8. Seat rear housing on output shaft rear bearing and countershaft. Use plastic or rawhide mallet to tap housing into place.
9. Install the three bolts that secure rear bearing retainer to rear housing as follows:
Fig. 97:
a. Apply Mopar Gasket Maker, or equivalent, to bolt threads, bolt shanks and under bolt heads (Fig. 97).
Fig. 98:
b. Start first two bolts in retainer (Fig. 98). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer.
c. Remove Pilot Stud 8120 and install last retainer bolt (Fig. 98).
d. Tighten all three retainer bolts to 30 - 35 Nm (22 - 26 ft. lbs.) torque.
ADAPTER HOUSING INSTALLATION-4WD
1. Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place.
Fig. 99:
2. Position rear bearing retainer in adapter housing (Fig. 99).
Fig. 100:
3. Apply Mopar Gasket Maker, or equivalent, to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 100).
4. Apply liberal quantity of petroleum jelly to countershaft, rear bearing and bearing race.
5. Install countershaft rear bearing in bearing race (Fig. 95).
CAUTION: The countershaft bearings can be installed backwards if care is not exercised. Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 95).
6. Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed.
7. Apply light coat of petroleum jelly to shift shaft bushing/bearing in adapter housing (Fig. 95).
8. Install adapter housing on geartrain.
9. Install rear bearing snap ring on output shaft (Fig. 100).
Fig. 101:
10. Lubricate lip of new rear seal (Fig. 101) with Mopar Door Ease, or transmission fluid.
11. Install new rear seal in adapter housing bore with Installer C-3860-A. Be sure seal is fully seat in housing bore (Fig. 101).
REVERSE IDLER SEGMENT INSTALLATION
1. Remove geartrain and housing assembly from fixture with aid of helper.
2. Apply Mopar Gasket Maker, or equivalent, sealer to underside of idler shaft bolt heads, bolt shanks and bolt threads (Fig. 97).
3. Align idler shaft and rear housing bolt holes with drift, pin punch, or Phillips screwdriver.
4. Work segment upward into housing and onto idler shaft.
5. Verify that idler shaft is seated in housing notch before proceeding. Segment and housing can be damaged if idler shaft is misaligned.
6. Insert idler shaft retaining bolts through housing and segment and into shaft. Long bolt goes through segment and short bolt goes through housing and directly into rear of shaft.
7. Tighten idler shaft bolts to 19 - 25 Nm (14 - 18 ft. lbs.) torque.
CAUTION: Make sure the idler shaft and support segment are properly seated and held firmly in place while tightening the shaft bolts. The segment, housing or shaft threads can be damaged if the idler shaft is allowed to shift out of position in the housing.
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET INSTALLATION
1. Before proceeding, verify that all synchro sleeves are in Neutral position (centered on hub). Move sleeves into neutral if necessary.
CAUTION: The transmission synchros must all be in Neutral position for proper reassembly. Otherwise, the housings, shift forks and gears can be damaged during installation of the two housings.
Fig. 102:
2. Install 3-4 shift fork in synchro sleeve (Fig. 102). Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.
Fig. 103:
3. Slide shift shaft through 3-4 shift fork (Fig. 103). Be sure shaft detent notches are to front.
Fig. 104:
4. Assemble shift shaft shift lever and bushing (Fig. 104). Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.
Fig. 105:
5. Install assembled lever and bushing on shift shaft (Fig. 105).
Fig. 106:
6. Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (Fig. 106).
Fig. 107:
7. Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 107).
8. Rotate shift shaft so detent notches in shaft are facing driver side of housing.
CAUTION: Correct positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 1800 off. If this occurs, the transmission will have to be disassembled again to correct shaft alignment.
Fig. 108:
9. Select correct new roll pin for shift shaft lever (Fig. 108). Shaft lever roll pin is approximately 22 mm (7/8 inch) long. Shift socket roll pin is approximately 33 mm (1-1/4 inch) long.
Fig. 109:
10. Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 109).
Fig. 110:
11. Seat shaft lever roll pin with pin punch (Fig. 110).
CAUTION: The shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.
12. Before proceeding, verify that lock pin slot in lever bushing is positioned as shown (Fig. 110).
Fig. 111:
13. Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 111).
Fig. 112:
14. Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation (Fig. 112).
15. Verify that notches in shift fork arms are aligned. Realign arms if necessary.
SHIFT TOWER AND LEVER ASSEMBLY INSTALLATION