M/T - Pops Out Of 1st Gear On Acceleration
NUMBER: 21-001-10 REV AGROUP: Transmission
DATE: April 20, 2010
THIS BULLETIN IS BEING PROVIDED IN ADVANCE PARTS ARE NOT EXPECTED TO BE AVAILABLE UNTIL APRIL 23, 2010 UNLESS THERE IS AN IMMEDIATE NEED, DO NOT ORDER PARTS UNTIL APRIL 23, 2010 ALL ORDERS WILL BE HELD UNTIL STOCK IS ON HAND.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-01-10, DATED MARCH 2, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PART NUMBERS FOR THE FIRST GEAR AND 1-2 SYNCHRONIZER KIT AND A REVISION TO THE 4X2 LABOR OPERATION NUMBER.
SUBJECT:
Manual Transmission Pops Out of Gear
OVERVIEW:
This bulletin involves verifying that the transmission shift boot is not interfering with the engagement of first gear and if not than replace the first gear and 1=2 synchronizer assembly.
MODELS:
2007 - 2010 KA/KK Nitro/Liberty
2007 - 2010 JK Wrangler
NOTE:
This bulletin applies to vehicles equipped with a manual transmission (sales code DEH)
SYMPTOM/CONDITION:
The transmission pops out of first gear while accelerating The condition may occur intermittently and may be difficult to diagnose.
DIAGNOSIS:
Verify that the shift boot is not causing the issue by ensuring the boot is not binding when in first gear In addition if the customer complains that the transmission pops out of gear in first, third, and fifth, than the shift boot would be most likely the cause for the complaint Refer to the appropriate service information regarding shift boot replacement If the shift boot is not causing the transmission to pop out of first gear, perform the following Repair Procedure.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Remove the transmission from the vehicle Follow the procedures identified in DealerCONNECT > TechCONNECT > Service Info > 21 Transmission and Transfer Case > Manual NSG3Y0 > Disassembly > Disassembly
2. Disassemble the transmission Follow the procedures identified in DealerCONNECT > TechCONNECT > Service Info > 21 Transmission and Transfer Case > Manual NSG3Y0 > Disassembly > Disassembly.
3. **Install the new first gear and the 12 synchronizer assembly (from kit p/n 63080512AB INTERNATIONAL ONLY or p/n 68085902AA NAFTA/LATIN AMERICA ONLY) onto the mainshaft** Follow the procedures identified in DealerCONNECT > TechCONNECT > Service Info > 21 Transmission and Transfer Case > Manual NSG37O>Assembly > Assembly.
NOTE:
When installing the synchronizer sleeve make sure that the side of the sleeve with the groove faces toward second gear
NOTE:
The selective snap rings are made available in case the mainshaft snap ring is damaged when disassembling the shaft Upon reassembly select the thickest snap ring that will fit properly in the snap ring groove
4. **Then reassemble the transmission using the new front countershaft seal and output shaft seal (from kit p/n 68080512AB INTERNATIONAL ONLY or p/n 63085902AA NAFTA/LATIN AMERICA ONLY)**
5. Install the transmission into the vehicle Follow the procedures identified in DealerCONNECT > TechCONNECT > Service Info > 21 Transmission and Transfer Case > Manual NSG370 > Installation > Installation
6. Fill the transmission with 15 L (317 pts) of Mopar(R) Manual Transmission Lubricant (p/n 04874464).
POLICY:
Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.