1993 DODGE TRUCK Service Repair Manual

- 24 NV4500
TRANSMISSION OVERHAUL

•
Fig. 82 1-2 Synchro Components

21
- 26
NV4500
TRANSMISSION
OVERHAUL

• LEGEND FOR

1.
MAINSHAFT
2. FIRST GEAR BEARING

3.
FIRST GEAR

4.
CLUTCH GEAR
5.
SYNCHRO STOP RING

6.
FIRST GEAR SNAP RING
7.
REVERSE
GEAR BEARING SPACER

8.
REVERSE
GEAR BEARING

9.
REVERSE
SYNCHRO SLEEVE

10.
SYNCHRO STRUTS AND SPRINGS
(3
EACH)

11.
REVERSE
GEARLINES
12.
THRUST WASHER
13. THRUST WASHER LOCATING
PIN
14.
MAINSHAFT REAR BEARING

15.
MAINSHAFT REAR BEARING CUP

16.
MAINSHAFT END PLAY SHIMS

17.
MAINSHAFT REAR BEARING PLATE

18.
MAINSHAFT
FIFTH
GEAR

19.
THRUST WASHER

20.
FIFTH
GEAR
NUT

21. MAINSHAFT SPLINE SEAL

22.
CLUTCH GEAR SNAP RING
23. FIRST
SPEED
CLUTCH GEAR

24.
FIRST GEAR SYNCHRO CLUTCH RING
FT GEMRTRAIN
25.
SYNCHRO HUB SNAP RING

26.
FIRST GEAR SYNCHRO STOP RING

27. 1-2
SYNCHRO SLEEVE

28.
SYNCHRO STRUTS AND SPRINGS
(4
EACH)

29.
1
-2
SYNCHRO HUB (INC. RETAINER
SPRINGS
AND WEIGHTS)

30.
SYNCHRO HUB SNAP RING
31. SECOND GEAR SYNCHRO STOP RING

32.
SECOND
SPEED
CLUTCH GEAR
33. SECOND GEAR SYNCHRO CLUTCH RING

34.
CLUTCH GEAR SNAP RING
35.
SECOND GEAR BEARING

36.
SECOND GEAR
37.
THRUST WASHER AND LOCATING
PIN
38.
THRUST WASHER SNAP RING

39.
THIRD
GEAR BEARING SPACER

40.
THIRD
GEAR
41.
THIRD
GEAR BEARING
ASSEMBLIES
(2)
42.
THIRD
GEAR SYNCHRO STOP RING

43.
3-4
SYNCHRO SLEEVE

44.
SYNCHRO STRUTS AND SPRINGS
(3
EACH)

45. 3-4
SYNCHRO HUB
46.
FOURTH
GEAR SYNCHRO STOP RING

47.
FOURTH
SPEED
CLUTCH GEAR

48.
DRIVE GEAR THRUST BEARING

TRANSMISSION
ASSEMBLY
AND ADJUSTMENT
Assembly
Information Gaskets are not used in the NV4500 transmis­

sion.
Use Mopar Gasket Maker, silicone adhe­
sive/sealer, or Loctite 518 on all gear case and
extension housing sealing surfaces.

Adjustment
Specifications
• Countershaft End Play: 0.051-0.15 mm (0.002-
0.006 in.)
• Mainshaft End Play: 0.051-0.15 mm (0.002-0.006 in.)

SPECIAL
TOOL SPECIAL TOOL Fig.
84 Installing Countershaft Front Bearing Cup
J9321-98

GEAR CASE ASSEMBLY (1) Install countershaft front bearing cup in case
with Tool Handle C-4171 and Installer Tool 6061-1 or C-4340 (Fig. 84).
(2) Install new bushings in shift lug rail bores
with Tool 6456 (Fig. 85). Seat bushings flush with

bores.

Fig.
85 Installing Shift Lug Rail
Bushings

(3) If case magnet was removed, install and secure
magnet in clip at bottom of case (Fig. 86).
Fig.
86 Gear
Case
Magnet
Installation

NV450I
TRANSMISSION OVERHAUL
21 - 27
COUNTERSHAFT AND REVERSE IDLER GEAR
INSTALLATION
(1) Install front bearing on countershaft with In­
staller Tool 6446 (Fig. 87).
Fig.
87 Countershaft Front Bearing
installation

(2) Lubricate countershaft front bearing cup and
cone with petroleum jelly.
(3) Position gear case on end with rear of case fac­
ing up (Fig. 88).
(4) Install countershaft in gear case (Fig. 88). Do
not install rear bearing on countershaft rear at
this time.
Fig.
88
Positioning
Countershaft In Gear
Case
(6) Install idler gear front thrust washer on boss in
gear case (Fig. 89). Coat thrust washer with liberal
quantity of petroleum jelly to hold it in place.
POSITION

IDLER

GEAR
Fig.
89
Positioning
Idler Gear Front Thrust
Washer
In
Case
(7) Install reverse idler gear in case (Fig. 90).
(8) Install idler gear rear thrust washer between
idler gear and case boss (Fig. 90).

REAR

THRUST

Fig.
90 Idler Gear And Thrust
Washer
Installation
(9) Align idler gear bearings and thrust washers
with drift. (10) Install reverse idler shaft (Fig. 91). Be sure
notched end of shaft is facing countershaft as shown.
Use shift cover bolt to hold and insert shaft in case

bore.

(11) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 92). (12) Install rear bearing cone on countershaft with
Installer Tool C-4040 or 6446 (Fig. 93).
(13) Remove wood block from under countershaft
and lower countershaft front bearing into front bear­
ing cup. (14) Install new front bearing cap in gear case
(Fig. 94). Apply Mopar silicone adhesive/sealer to (5) Lubricate reverse idler gear bearings with pe­
troleum jelly and install first bearing, bearing spacer and second bearing (Fig. 89).

21
- 28
N¥4500
TRANSMISSION
OVERHAUL

COUNTERSHAFT
SHIFT

COVER
BOLT
REVERSE

IDLER

SHAFT

Fig.
91
Reverse
idler
Shaft
Installation

WOOD,
BLOCK

J9221-165

COUNTERSHAFT
Fig.
92
Supporting
Countershaft
With
Wood
Block

flange and lip of new cap. Then seat cap in case bore
with wood block and mallet. (15) Lubricate countershaft rear bearing cup and
cone with petroleum jelly.
(16) Install countershaft rear bearing cup in gear
case and over rear bearing (Fig. 95). Tap cup into
place with plastic mallet if necessary.

ADJUSTING
COUNTERSHAFT
END
PLAY
(1) Install countershaft rear bearing plate (Fig.

96).
Be sure plate is seated in notch in reverse idler
shaft before tightening bearing plate bolts.
(2) Rotate countershaft 4-5 times to seat bearings.
(3) Mount dial indicator on case. Then position in­
dicator plunger on end of countershaft and zero indi­
cator dial needle (Fig. 97).
COUNTERSHAFT

SPECIAL

TOOL
6446

REAR

BEARING

_ J9221-166

Fig.
93 Installing Countershaft Rear Bearing
FRONT

BEARING
CAP

(SEAT

WITH

WOOD
BLOCK)
^ , ( /
J9221-172

Fig.
94 Countershaft Front Bearing Cap
Installation
COUNTERSHAFT
REAR

BEARING
CUP

J9221-167

Fig.
95 Countershaft Rear Bearing Cup
Installation
(4) Raise countershaft with screwdriver and note
end play reading on dial indicator. End play should
be 0.051 - 0.15 mm (0.002 - 0.006 in.).
(5) Remove countershaft rear bearing plate.
(6) Select and install end play shim that will pro­
vide minimum countershaft end play. Position shim
on rear bearing cup (Fig. 98). (7) Reinstall countershaft rear bearing plate (Fig.

96).
Be sure plate is seated in reverse idler shaft notch before installing bolts. Also be sure end play

•

NV4600 TRANSMISSION OVERHAUL
21 - 29

COUNTERSHAFT
REAR

BEARING
PLATE
IDLER
SHAFT

J9221-168

Fig.
96 Countershaft Rear Bearing
Plate
installation

DIAL
INDICATOR
INDICATOR
MOUNTING
ARM
AND

BASE

J922M69 Fig.
97
Measuring
Countershaft End Play

REAR

BEARING
CUP
END

PLAY
SHIM
(SELECTIVE) Fig.
98 Installing Countershaft End Play
Shim

shims are still in position before tightening bearing
plate bolts. (8) Apply 1-2 drops Mopar Loc N' Seal or Loctite
242 to threads of rear bearing plate bolts. Then in­
stall and tighten bearing plate bolts to 23 Nnn (200
in. lbs.) torque.

SHIFT
LUG AND
RAIL
INSTALLATION
(1) Lubricate shift lug, rail and bushings with Cas-
trol Syntorq. (2) Insert shift lug rail part way into case.
(3) Install shift lug on rail. Note position of
(4) Position shift rail so roll pin notches are at ap­
proximately 5 o'clock position (Fig. 99).
(5) Install roll pin that secures lug to rail (Fig. 99).
NOTCHES

(FOR 5TH GEAR SHIFT FORK ROLL PINS) LUG
RAIL
SHIFT
LUG
J922M71 Fig.
99 Shift Lug And Rail
Installation
MAINSHAFT
AND
GEARTRAIN ASSEMBLY

CAUTION:
The
reverse,
1-2 and 3-4
synchro compo­ nents
can be
assembled
and
installed incorrectly
if

care
is not
exercised. Some components
can be in­

stalled backwards resulting
in
shift problems. Refer
to
the
assembly procedures
for
component
identifi­
cation
and
location.

(1) Lubricate mainshaft bearing surfaces and all
bearing assemblies with Castrol Syntorq or with pe­
troleum jelly.
(2) Install first snap ring in rearmost groove of
mainshaft hub (Fig. 100). This snap ring locates first speed clutch gear on shaft. A total of four of these
snap rings are used to secure various components on
the mainshaft 1-2 synchro hub. The snap rings are all the same size and are interchangeable.
(3) Install first gear bearing assembly on main-
shaft (Fig. 100).
(4) If desired, mainshaft can be placed in upright
(vertical) position and supported with wood blocks
(Fig. 101). Reverse gear components are easier to in­
stall with shaft upright. (5) Install first gear and bearing on shaft (Fig.

101).
Clutch hub side of gear faces front of shaft.

21
- 30
NV4500
TRANSMISSION
OVERHAUL

•

SNAP
RING
FIRST

-GEAR

BEARING

MAINSHAFT
SYNCHRO
HUB
J9221-176

Fig.
100 First Gear Bearing
and
Snap
Ring
Installation
(6) Install clutch gear
on
first gear
(Fig. 101). Be

sure clutch gear
is
seated
on
shaft splines. (7) Install first gear snap ring
(Fig. 101). Use

heavy duty snap ring pliers
to
install this snap ring as ring tension
is
considerable.
Do not
overspread
snap ring
and
make sure
it is
fully seated
in

groove. Reverse gear will
not fit
properly
if
snap
ring
is not
fully seated.
FIRST

GEAR
FIRST

GEAR
SNAP
RING

REVERSE
CLUTCH
GEAR

J9221-177
Fig.
101 First Gear,
Clutch
Gear
And
Snap
Ring

Installation

(8) Install stop ring
on
clutch gear
(Fig. 102). Be

sure stop ring
is
fully seated
on
gear taper.
(9) Install reverse gear bearing spacer
on
main-
shaft
(Fig. 103).
Bearing spacer seats against first
gear snap ring. (10) Install reverse gear bearing
on
mainshaft
(Fig.
103).

(11)
If
reverse gear sleeve
and
struts were disas­
sembled
for
service, reassemble sleeve, struts
and

springs
as
follows:
WOOD
BLOCKS
REVERSE
GEAR

STOP
RING

XLUTCH
GEAR
-FIRST
GEAR

\-
-• ~ • - - x J9221-191
i

Fig.
102
Clutch
Gear
Stop
Ring
Installation

REVERSE
GEAR
BEARING
BEARING
SPACER

FIRST

GEAR

J9221-192
Fig.
103
Reverse
Gear Bearing
And
Spacer

Installation

CAUTION:
The
reverse
sleeve
will
fit
either
way
on

the
hub.
This
means
the
sleeve
can be
installed
backwards
if
care
is not
exercised.
Be
sure
the ta­

pered
side
of the
sleeve
faces
rearward
after
instal­
lation.

(a) Position sleeve
on hub so
tapered side
of

sleeve faces rearward. Sleeve will
fit
either
way

but will cause shift problems
if
installed backwards (Fig.
104).
(b) Rotate sleeve
to
align teeth
on
sleeve
and

hub.
Sleeve will slide easily into place
on hub

when properly aligned. (c) Install springs
in
gear
hub (Fig. 104). Use pe­

troleum jelly
to
hold springs
in
place
if
desired.
(d) Compress first spring with flat blade screw­
driver
and
slide strut into position
in hub
slot.
Then work spring into seat
in
strut with small
hooked tool,
or
screwdriver.
(e) Install second
and
third struts
in
same man­
ner
as
described
in
step
(d).
(f) Work sleeve upward
on hub
until struts
are

centered
and
seated
in
sleeve. Sleeve should
be in

neutral position after seating struts.

•

HUB
J922M89
Fig.
104 Reverse Gear Synchro Assembly (12) Install reverse gear and synchro assembly on
mainshaft (Fig. 105). Rotate assembly until stop ring lugs engage in hub slots and gear drops into fully
seated position.

Fig.
105
Reverse
Gear
Installation

(13) Install reverse gear thrust washer pin in main-
shaft (Fig. 106). Use needle nose pliers to install pin.
(14) Install reverse gear thrust washer (Fig. 107).
Be sure locating pin is seated in thrust washer notch.
(15) Install rear bearing on mainshaft. Use In­
staller Tool 6446 to seat bearing on shaft and against
thrust washer (Fig. 108). If bearing is not fully seated on shaft, seat bearing by tapping inner race
with small brass punch and hammer. Bearing inner
race should be flush with shaft.
(16) Turn mainshaft over and place it in horizontal
position on workbench.
(17) Install first speed clutch gear on mainshaft
1-2 synchro hub (Fig. 109). Recessed side of gear
faces front. Be sure gear is seated against snap ring
previously installed on hub.
(18) Install snap ring on mainshaft 1-2 synchro
NV4I00
TRANSMISSION OVERHAUL
21 - 31

Fig.
106 Thrust
Washer
Pin
Installation
Fig.
107
Reverse
Gear Thrust
Washer
Installation

Fig.
108 Installing Mainshaft Rear Bearing
hub to secure clutch gear (Fig. 110). Be sure snap
ring is fully seated in hub groove and against clutch gear. Note that this is second of four snap rings used
to secure synchro components on shaft hub.
(19) Assemble first speed clutch ring and stop ring
(Fig. 111). (20) Install assembled first speed clutch and stop
rings on clutch gear (Fig. 112). Be sure tabs on clutch ring are aligned and seated in first gear