Part 2 of 2

NV3500 - Manual Transmission
ASSEMBLY
PART......................2 of 2








GEARTRAIN ASSEMBLY
1. Install Adapter 6747-1A on input shaft hub of Fixture 6747 (Fig. 81). Then install Adapter 6747-2B on front bearing hub of countershaft. Be sure the shoulder is seated against the countershaft.






2. Install input shaft in fixture tool with Adapter Tool 6747-1A positioned under the shaft as shown (Fig. 82).
3. Install pilot bearing in input shaft (Fig. 82).

NOTE: The side of the pilot bearing with the small diameter goes toward the input shaft.






4. Install fourth gear synchro ring on input shaft (Fig. 83).






5. Adjust height of idler gear pedestal on fixture (Fig. 84). Start with a basic height of 18.4 cm (7-1/4 inch). Final adjustment can be made after gear is positioned on pedestal.






6. Install assembled output shaft and geartrain in input shaft (Fig. 85). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
7. Install Adapter 6747-2B on front bearing hub of countershaft, if not previously done. The shoulder goes toward the countershaft.






8. Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding (Fig. 86).
9. Check alignment of countershaft and output shaft gear teeth. 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 will not interfere with assembly. If difference is greater than this, the countershaft adapter tool is probably upside down.






10. Position reverse idler in support cup of fixture (Fig. 87). Verify idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out from the geartrain. Adjust pedestal up or down if necessary and verify short end of idler shaft is facing up as shown.






11. On 2-wheel drive transmission, thread one Alignment Pin 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (Fig. 88).






12. Assemble 1-2 and fifth reverse-shift forks (Fig. 89). Arm of fifth-reverse fork goes through slot in 1-2 fork.






13. Install assembled shift forks in synchro sleeves and verify forks are seated in sleeves (Fig. 90).




ADAPTER HOUSING - 4WD

NOTE: Transmission shift components must be in Neutral to prevents damaging to the synchro and shift components when installing the housings.

1. Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place.






2. Position rear bearing retainer in adapter housing (Fig. 97).
3. Apply Mopar Gasket Maker or equivalent to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 95).
4. Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race.
5. Install countershaft rear bearing in bearing race (Fig. 93).

NOTE: Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 93).

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. 93).
8. Install adapter housing on geartrain.






9. Install rear bearing snap ring on output shaft (Fig. 98).






10. Lubricate lip of new rear seal (Fig. 99) with Mopar Door Ease, or transmission fluid.
11. Install new rear seal in adapter housing bore with Installer C-3860-A. Verify seal is seated in housing bore (Fig. 99).




SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET
1. Verify all synchro sleeves are in Neutral position (centered on hub).

CAUTION: Transmission synchros must all be in Neutral position to prevent damaging the housings, shift forks and gears while installing the housings.






2. Install 3-4 shift fork in synchro sleeve (Fig. 100). Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.






3. Slide shift shaft through 3-4 shift fork (Fig. 101) with shaft detent notches to the rear.






4. Assemble shift shaft shift lever and bushing (Fig. 102). Verify slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.






5. Install assembled lever and bushing on shift shaft (Fig. 103).






6. Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (Fig. 104).






7. Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 105).
8. Rotate shift shaft, so detent notches in shaft are facing the TOP of the transmission housing.

CAUTION: Both shaft roll pins can be installed when the shaft is 180° off. If this occurs, the transmission will have to be disassembled again to correct shaft alignment.






9. Select correct new roll pin for shift shaft lever (Fig. 106). 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.






10. Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 107).






11. Seat shaft lever roll pin with pin punch (Fig. 108).

CAUTION: 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. Verify that lock pin slot in lever bushing is positioned as shown (Fig. 108).






13. Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 109).






14. Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket after installation (Fig. 110).






15. Verify that notches in shift fork arms are aligned (Fig. 111). Realign arms if necessary.
16. Rotate shift lever and bushing downward to expose detent bore in the lever.






17. Install detent spring then the ball into the detent bore (Fig. 112) and hold the ball in the lever. Then rotate the lever upward into the fork arm notches.

NOTE: Verify detent ball is seated in the fork arms before proceeding.







FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
1. If previously removed, install input shaft bearing in front housing bore (Fig. 113). Install snap ring and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.






2. Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (Fig. 113). Large diameter side of bearing cage goes toward countershaft (Fig. 114). Small diameter side goes toward bearing race in housing.
3. Reach into countershaft front bearing with finger and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place during housing installation.
4. Apply small amount of petroleum jelly to shift shaft bushing in front housing.






5. Apply 1/8 inch wide bead of Mopar Gasket Maker or equivalent to mating surfaces of front and rear housings (Fig. 115).
6. Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain.
7. Work front housing downward onto geartrain until seated on rear housing.

CAUTION: Front housings will not seat if shift components are not in Neutral or one or more components are misaligned. Do not force the front housing into place.

8. Tap rear housing alignment dowels back into place with hammer and pin punch. Both dowels should be flush fit in each housing. Have helper hold transmission upright while dowels are tapped back into place.
9. Place transmission in horizontal position.






10. Apply Mopar Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 116).
11. Install and start housing attaching bolts by hand (Fig. 116).
Then tighten bolts to 34 Nm (25 ft. lbs.).






12. Install shift shaft bushing lock bolt (Fig. 117). Apply Mopar Gasket Maker or equivalent to bolt threads, shank and underside of bolt head before installation.

CAUTION: If lock bolt cannot be fully installed the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned.






13. Lubricate then install shift shaft detent plunger in housing bore (Fig. 118). Lubricate plunger with semi-synthetic/synthetic grease. Verify plunger is fully seated in detent notch in shift shaft.
14. Install detent spring inside plunger (Fig. 118).
15. Install detent plug in end of Installer 8123. Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore. Drive detent plug into transmission case until plug seats.






16. Install backup light switch (Fig. 119).






17. Install input shaft snap ring (Fig. 120).






18. Install new oil seal in front bearing retainer with Installer 6448 (Fig. 121).






19. Apply bead of Mopar silicone sealer or equivalent to flange surface of front bearing retainer (Fig. 122).






20. Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 123). Verify bolt holes are aligned before seating retainer.

CAUTION: Be sure sealer does not get into the oil feed hole in the transmission case or bearing retainer.






21. Install and tighten bearing retainer bolts to 7 - 10 Nm (5 - 7 ft. lbs.) (Fig. 124).

SHIFT TOWER AND LEVER
1. Apply petroleum jelly to ball end of shift lever and interior of shift socket.
2. Shift the transmission into third gear.






3. Align and install shift tower and lever assembly (Fig. 125). Be sure shift ball is seated in socket and the offset in the tower is toward the passenger side of the vehicle before installing tower bolts.






4. Install shift tower bolts (Fig. 126) and tighten bolts to 8.5 Nm (75.2 inch lbs.).
5. Fill transmission to bottom edge of fill plug hole with lubricant.
6. Install and tighten fill plug to 34 Nm (25 ft. lbs.).
7. Check transmission vent. Be sure vent is open and not restricted.