Cleaning and Inspection

CLEANING / NV1500 Manual Transmission
Clean the gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk, or similar solvents. Do not dry the bearings with compressed air. Allow the bearings to either air dry, or wipe them dry with clean shop towels.

INSPECTION / NV1500 Manual Transmission

NOTE: Minor burrs, nicks or scratches on components can be smoothed with 320/400 grit emery soaked in oil and polishing with crocus cloth.

SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball or internal components are worn or damaged.








SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro sleeve contact surfaces (Fig. 32). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks.

Check condition of the shift shaft detent plunger and spring. The plunger should be smooth and free of nicks or scores. The plunger spring should be straight and not collapsed or distorted. Replace the plunger and spring if in doubt about condition. Check condition of detent plunger bushings. Replace if damaged.

Inspect the shift shaft, shift shaft bushing and bearing, the shaft lever and the lever bushing that fits over the lever. Replace the shaft if bent, cracked, or severely scored. Replace the shift shaft bushing or bearing if damaged.

Replace the shaft lever and bushing if either part is deformed, or worn. Do not attempt to salvage these parts, as shift fork binding will occur. Replace the roll pin that secures the lever to the shaft.



FRONT/REAR HOUSINGS AND BEARING RETAINERS
Inspect the housing's cracks, stripped threads, scored mating surfaces, damaged bearing bores or worn dowel pin holes. Minor nicks on mating surfaces can be dressed off with a fine file or emery cloth.

NOTE: The front housing contains the countershaft front bearing race. The rear housing contains the countershaft rear bearing race. If a countershaft bearing failure results, the bearing races must be replaced also.

Inspect input shaft bearing retainer. Be sure the release bearing slide surface of the retainer is in good condition. Replace the retainer seal if necessary.

Inspect output shaft bearing retainer and verify U-shaped retainer is flat and free of distortion. Replace the retainer if the threads are damaged or if the retainer is bent or cracked.


COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings are standard tapered roller bearings with matching races. The races are pressed into the front and rear housings. Inspect countershaft bearings and races for abnormal wear or damage.






REVERSE IDLER COMPONENTS
Inspect idler gear, bearing, shaft, thrust washer and support for excessive wear or failure (Fig. 33). Replace bearing, if needle bearing rollers are worn, chipped, cracked, flat-spotted, brinnelled or if plastic bearing cage is damaged or distorted.

Replace thrust washer, if cracked, chipped or worn. Replace idler gear if the teeth are chipped, cracked or worn thin. Replace shaft if worn, scored or the bolt threads are damaged beyond repair. Replace support segment if cracked or chipped and replace the idler attaching bolts if the threads are damaged.


Shift Socket
Inspect shift socket for wear or damage. Replace socket if the roll pin or shift shaft bores are damaged. Replace socket if the ball seat is worn, or cracked. Never reuse the original shift socket roll pin. The socket roll pin is approximately is approximately 33 mm (1-1/4 inch) long.


Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or broken teeth. Check condition of the bearing bore in each gear. The bores should be smooth and free of surface damage. Discoloration of the gear bores is a normal occurrence and is not a reason for replacement. Replace gears only when tooth damage has occurred or if the bores are brinnelled or severely scored.

Inspect shaft splines and bearings surfaces. Replace the shaft if the splines are damaged or bearing surfaces are deeply scored, worn or brinnelled.