Part 2 of 2

ASSEMBLY / NV3550 Manual Transmission Part 2






GEARTRAIN ASSEMBLY
1. Install Adapter 6747-1A on input shaft hub of Fixture 6747 (Fig. 85).






2. Install input shaft in fixture and make sure Adapter 6747-1A is positioned under shaft as shown (Fig. 86).
3. Install pilot bearing in input shaft (Fig. 86).

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. 87).






5. Adjust height of idler gear pedestal on assembly fixture (Fig. 88). Start with a basic height of 18.4 cm (7-1/4 in.). Final adjustment can be made after gear is positioned on pedestal.






6. Install assembled output shaft and geartrain in input shaft (Fig. 89). 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. The adapter has a shoulder on one side that goes towards the countershaft.






8. Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are meshed with the mainshaft gears (Fig. 90).
9. Check alignment of countershaft and output shaft gear teeth. Note gears may not align perfectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This difference will not interfere with assembly.






10. Position reverse idler in support cup of assembly fixture (Fig. 91). Ensure idler gear is properly meshed and aligned with shaft gear teeth, and bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary and verify that 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. 92).






12. Assemble 1-2 and fifth reverse-shift forks (Fig. 93). Arm of fifth-reverse fork goes through slot in 1-2 fork.






13. Install assembled shift forks in synchro sleeves (Fig. 94). Verify forks are properly seated in sleeves.



ADAPTER HOUSING - 4WD
1. Install rear bearing in adapter housing, by tapping it into place with a wood hammer handle or wood dowel.






2. Position rear bearing retainer in adapter housing (Fig. 101).
3. Apply Mopar Gasket Maker or equivalent to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 99).
4. Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race.
5. Install countershaft rear bearing in bearing race (Fig. 97).

CAUTION: The large diameter side of the roller retainer must face the countershaft and the small diameter side must face the race and housing (Fig. 97).

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. 97).
8. Install adapter housing on geartrain.






9. Install rear bearing snap ring on output shaft (Fig. 102).






10. Lubricate lip of new rear seal (Fig. 103) 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. 103).



SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET

CAUTION: Transmission synchros must be in the Neutral position, to prevent damage to the housings, shift forks and gears during installation of the two housings.






1. Install 3-4 shift fork in synchro sleeve (Fig. 104). Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.
2. Slide the end of shift shaft with shaft detent notches through 3-4 shift fork.






3. Assemble shift shaft shift lever and bushing (Fig. 105). The slot in bushing must face up and roll pin hole for lever must be aligned with hole in shaft.






4. Install assembled lever and bushing on shift shaft (Fig. 106).









5. Slide shift shaft through forks (Fig. 107) and into shift lever opening in rear housing (Fig. 108).






6. Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 109).
7. 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.






8. Select correct new roll pin for shift shaft lever (Fig. 110). Shaft lever roll pin is approximately 22 mm (7/8 in.) long. Shift socket roll pin is approximately 33 mm (1-1/4 in.) long.






9. Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 111).






10. Seat shaft lever roll pin with pin punch (Fig. 112).

CAUTION: The shaft lever roll pin must be flush with the surface of the lever or lever bushing will bind on the roll pin.

11. Verify lock pin slot in lever bushing is positioned as shown (Fig. 112).






12. Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 113).






13. Seat roll pin flush in shift socket with pin punch (Fig. 114).






14. Verify notches in shift fork arms are aligned (Fig. 115). Realign arms if necessary.
15. Rotate shift lever and bushing downward to expose detent bore (Fig. 115) in the lever.






16. Install detent spring then the ball into the detent bore (Fig. 116) 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. Install input shaft bearing in front housing (Fig. 117). 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. 117). Large diameter side of bearing cage goes toward countershaft (Fig. 118). 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. 119).
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 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. 120).
12. Install and start housing attaching bolts by hand (Fig. 120). Then tighten bolts.

housing attaching bolts 34 Nm (25 ft. lbs.).






13. Install shift shaft bushing lock bolt (Fig. 121). Apply Mopar Gasket Maker or equivalent to bolt threads, shank and underside of bolt head before installation.

CAUTION: If the lock bolt cannot be seated, 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 Valvoline Dura Blend semi-synthetic/synthetic grease or equivalent.

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. 122).






18. Install input shaft snap ring (Fig. 123).






19. Install new oil seal in front bearing retainer with Installer 6448 (Fig. 124).






20. Apply bead of Mopar silicone sealer or equivalent to flange surface of front bearing retainer (Fig. 125).






21. Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 126). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.

CAUTION: Do not allow sealer to get into the oil feed hole in the transmission case or bearing retainer.






22. Install and tighten bearing retainer bolts.(Fig. 127).


bearing retainer bolts 7 - 10 Nm (5 - 7 ft. lbs.)


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. 128). 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. 129).

shift tower bolts 8.5 Nm (75.2 in. lbs.).


5. Fill transmission to bottom edge of fill plug hole with Mopar Transmission Lubricant.
6. Install and tighten fill plug.

fill plug 34 Nm (25 ft. lbs.).

7. Check transmission vent. Be sure vent is open and not restricted.