Cleaning and Inspection

CLEANING / NV3500 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 / NV3500 Manual Transmission

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

SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace 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. 48). 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 housings for 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. Be advised that these components are NOT serviceable items. The front housing will have to be replaced if the countershaft bearing race is loose, worn, or damaged. The rear housing will have to be replaced if the countershaft rear bearing race is loose, worn, or damaged.

Inspect input shaft bearing retainer. Verify release bearing slide surface of the retainer is in good condition.
Inspect output shaft bearing retainer. Verify U-shaped retainer is flat and free of distortion. Replace retainer if the threads are damaged or if the retainer is bent or cracked.


COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine lapped during manufacture to form matched sets. The bearings and races should not be interchanged.

NOTE: The bearing races are a permanent press fit in the housings and are NOT serviceable. If a bearing race becomes damaged, it will be necessary to replace the front or rear housing as necessary. A new countershaft bearing will be supplied with each new housing for service use.






The countershaft bearings can be installed backwards if care is not exercised. The bearing roller cage is a different diameter on each side. Be sure the bearing is installed so the large diameter side of the cage is facing the countershaft gear (Fig. 49). The small diameter side goes in the bearing race.

REVERSE IDLER COMPONENTS
Inspect idler gear, bearing, shaft, thrust washer, wave washer and thrust plate. Replace bearing if any of the needle bearing rollers are worn or brinnelled or the plastic bearing cage is damaged or distorted.
Replace thrust washer, wave washer or thrust plate if cracked, chipped or worn. Replace idler gear if the teeth are chipped, cracked or worn thin. Replace the shaft if worn, scored or 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 worn, cracked, roll pin or shift shaft bores are damaged. Never reuse a shift socket roll pin. Install a new pin during reassembly. The socket roll pin is approximately is approximately 33 mm (1-1/4 inch) long.

Output Shaft And Geartrain
Inspect all of the gears for worn, cracked, chipped or broken teeth. Also 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 the shaft splines and bearings surfaces. Replace shaft if the splines are damaged or bearing surfaces are deeply scored, worn or brinnelled.