Part 2 of 2

ASSEMBLY / NV3500 Manual Transmission Part 2

ADAPTER HOUSING - 4WD
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. 98).
3. Apply Mopar Gasket Maker or equivalent, to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 96).
4. Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race.
5. Install countershaft rear bearing in bearing race (Fig. 94).

CAUTION: Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 94).

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. 94).
8. Install adapter housing on geartrain.






9. Install rear bearing snap ring on output shaft (Fig. 99).






10. Lubricate lip of new rear seal (Fig. 100) 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. 100).



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

CAUTION: The transmission synchros must all be in Neutral position for assembly. Otherwise the housings, shift forks and gears can be damaged during installation of the two housings.






2. Install 3-4 shift fork in synchro sleeve (Fig. 101). Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.
3. Slide the end of shift shaft with shaft detent notches through 3-4 shift fork.






4. Assemble shift shaft shift lever and bushing (Fig. 102). Be sure, 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: Positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even 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: 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. 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 (Fig. 110).






15. Verify notches in shift fork arms are aligned (Fig. 111). Realign arms if necessary.
16. Rotate shift lever and bushing downward to expose detent bore (Fig. 111) 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. Install reverse blocker, retainer and retainer bolt in front housing.






2. If previously removed, input shaft bearing in front housing (Fig. 113). Install snap ring and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.






3. 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.
4. 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. This avoids having rollers becoming displaced during housing installation.
5. Apply small amount of petroleum jelly to shift shaft bushing in front housing.






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

CAUTION: If the front housing will not seat on the rear housing, either the shift components are not in Neutral, or one or more components are misaligned. Do not force the front housing into place. This will only result in damaged components.

9. 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.
10. Place transmission in horizontal position.






11. 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).
12. Install and start housing attaching bolts by hand (Fig. 116). Then tighten bolts to 34 Nm (25 ft. lbs.).






13. 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 the lock bolt cannot be fully installed, do not try to force it into place. Either the shift shaft is not in Neutral or the shaft bushing (or lever) is misaligned.

14. Lubricate then install shift shaft detent plunger in housing bore. Lubricate plunger with semi-synthetic/synthetic grease.

NOTE: Verify plunger is fully seated in detent notch in shift shaft.

15. Install detent spring inside plunger.
16. Install plug on detent spring and compress spring. Then drive detent plug into transmission case until plug seats.






17. Install backup light switch (Fig. 118).






18. Install input shaft snap ring (Fig. 119).






19. Install new oil seal in front bearing retainer with Installer 6448 (Fig. 120).






20. Apply bead of Mopar silicone sealer or equivalent to flange surface of front bearing retainer (Fig. 121).






21. Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 122). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.

NOTE: Ensure no sealer gets into the oil feed hole in the transmission case or bearing retainer.






22. Install and tighten bearing retainer bolts to 7 - 10 Nm (5 - 7 ft. lbs.) (Fig. 123).



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. 124). 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. 125). Tighten bolts to 8.5 Nm (75.2 inch lbs.).
5. Fill transmission to bottom edge of fill plug hole with Mopar Transmission Lubricant or equivalent.
6. Install and tighten fill plug to 34 Nm (25 ft. lbs.).