1993 DODGE TRUCK Bearing nut torque

21
- 8
NV4500
TRANSMISSION OVERHAUL
———— ^ ____ - #

CLUTCH
GEAR J9221-89

Fig. 9 Removing Countershaft Fifth Speed Clutch Gear Snap Ring
FIFTH GEAR
SHIFT FORK
J9221-94

Fig. 10 Removing Fifth Gear Shift Fork Roil Pins
(3) Remove shift fork and fifth gear components as
assembly. Rotate mainshaft as needed to allow coun­
tershaft fifth gear to clear mainshaft fifth gear.

Removing
Countershaft
Fifth
Gear
Components
Individually
(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 9). (2) Remove countershaft fifth speed clutch gear,
stop ring and bearing spacer (Fig. 11).
(3) Remove three struts and strut springs from
countershaft fifth gear hub and sleeve (Fig. 11). (4) Remove mainshaft fifth gear nut and washer as
follows:
(a) Install Nut Wrench 6443 on fifth gear nut
(Fig. 12). Note that wrench only fits one way on
nut. Be sure wrench is fully engaged in nut slots and is not cocked.
(b) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel drive models, install Socket Wrench 6442 on main-
shaft splines. Then install breaker bar in socket wrench (Fig. 13). Wedge breaker bar handle
J9221-90
GEAR

Fig. 11 Removing Countershaft Fifth Gear Synchro Components against workbench. Purpose of socket wrench and
breaker bar is to prevent mainshaft from turning
while nut is loosened.
(c) Position small end of Nut Wrench 6443 at ap­
proximately 10 o'clock position (Fig. 12).
(d) Strike small end of Nut Wrench 6443 with
heavy copper hammer to break nut loose. Nut is se­
cured by interference fit thread plus Loctite adhe­ sive and will require several firm blows to loosen it
(nut torque is in 300 ft. lb. range). (e) Once nut is loose, it can be removed by hold­
ing nut wrench with breaker bar and rotating out­
put shaft with socket wrench and ratchet.
(f)
Remove fifth gear nut and coned washer from
shaft (Fig. 14). Note position of washer for assem­
bly reference (coned side of washer faces rear). SPECIAL
STRIKE
NUT J9221-91

Fig. 12 installing Nut Wrench On Mainshaft Fifth Gear

NV4500
TRANSMISSION
OVERHAUL
21 - 39

MAINSHAFT
END
PLAY
ADJUSTMENT

(1) Install mainshaft rear bearing
cup in
case
and

over bearing.
Tap
bearing
cup
into place with plastic
mallet. (2) Install rear bearing plate
to
hold mainshaft
and rear bearing
in
position (Fig. 145).
Do not
install
any
end
play shims
at
this time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case
in
upright position
on
bench.
Either
cut
hole
in
bench
to
accept drive gear
and

front retainer,
or use
C-clamps
to
secure transmis­ sion
on
bench.
Do not
leave transmission unsup­
ported.
(5) Mount dial indicator
on
rear
of
gear case
and

position indicator plunger against inner race
of
rear
bearing (Fig.
145).

(6) Move mainshaft forward
to
remove
all
play.
Then zero dial indicator.
(7) Move mainshaft upward
and
observe dial indi­
cator reading. Move mainshaft with
pry
tool posi­
tioned between drive gear
and
case. (8)
End
play should
be
0.051-0.15
mm
(0.002-0.006

in.).
Select
fit
shims
are
available
to
adjust
end
play
if necessary.
DIAL
INDICATOR AND
BASE REAR
BEARING
(j
POSITION
J INDICATOR

(J
PLUNGER
.

L/L-ON
BEARING-
(/ INNER RACE
J9221-232

Fig.
145
Checking
Mainshaft End Play
(9)
If end
play adjustment
is
required, remove
bearing plate
and
install necessary shim. (10) Reinstall rear bearing plate
(Fig. 146).

Tighten rear bearing plate bolts
to 23 N*m (200 in.
lbs.) torque.
Be
sure
oil
hole
in
bearing plate
is at

top
as
shown.

MAINSHAFT
FIFTH
GEAR
INSTALLATION
(1) Install mainshaft fifth gear.
Use
Installer Tool
6446
to
seat gear
on
shaft (Fig. 147). Gear
is
seated
when
it
contacts rear bearing.
(2) Install fifth gear
nut
washer (Fig. 148). Coned
side
of
washer faces
end of
shaft.
(3) Apply
3-4
drops Mopar Lock
N'
Seal,
or
Loctite
242
to nut
threads
on
mainshaft. BEARING
PLATE
OIL HOLE
(AT
TOP) MAINSHAFT
REAR
BEARING PLATE

J9221-233

Fig.
146 Rear Bearing
Plate
Installation
MAINSHAFT FIFTH
GEAR SPECIAL
TOOL
6446
J9221-220

Fig.
147 Installing Mainshaft
Fifth
Gear
(4) Install fifth gear
nut on
mainshaft (Fig.
148).

FIFTH
GEAR NUT
WASHER
'(CONED)
FIFTH
GEAR NUT

J9221-93

Fig.
148 Installing
Fifth
Gear Nut And
Washer

(5) Tighten fifth gear
nut as
much
as
possible with
Nut Wrench
6443,
long handle ratchet, breaker
bar
and Socket Wrench 6441
or
6442 (Fig.
149).

21
- 40
NV4500
TRANSMISSION
OVERHAUL

SPECIAL

TOOL
6443
FIFTH

GEAR

NUT

SPECIAL
TOOL
6441
OR

6442

RATCHET

WRENCH
BREAKER

BAR

J9221-92

Fig.
149 Fifth Gear
Nut
installation (6) Lock mainshaft gears
by
shifting
all
synchro
sleeves into engaged position, (7) Position Spline Socket Wrench
6441 or
6442
on

mainshaft splines. Then install breaker
bar in
socket
wrench
and
wedge
bar
against workbench. (8) Tighten fifth gear
nut
with
Nut
Wrench 6443
and high capacity torque wrench. Required torque
on

nut
is
339-475
N*m
(250-350
ft.
lbs.). Have helper
hold transmission steady
if
necessary.
Nut can
also
be tightened
by
striking Wrench 6443 with heavy- copper mallet then checking with torque wrench.

COUNTERSHAFT
FIFTH
GEAR
AND
SYNCHRO

INSTALLATION
(1) Install thrust washer
pin in
countershaft
(Fig.

150).
0/

COUNTERSHAFT

J9221-234

Fig.
150 Installing Fifth Gear Thrust Washer Pin (2) Install thrust washer
on
countershaft. Turn
washer until
pin
engages
in
washer notch
(Fig. 151).
Flat side
of
washer faces rear
and
cone side
to
front as shown.
J9221-235

Fig.
151 installing
Fifth
Gear Thrust
Washer
(3) Lubricate
and
install fifth gear bearings
on

countershaft
(Fig. 152).

(4) Install bearing spacer
on
countershaft
and
seat
it against bearings
(Fig. 152).
Coat spacer with
pe­

troleum jelly
to
hold
it in
place.
.BEARING

SPACER
FIFTH

GEAR

BEARINGS
J9221-236

Fig.
152 Countershaft
Fifth
Gear Bearing And
Spacer
Installation
(5) Install synchro sleeve
on hub of
countershaft
fifth gear. Tapered side
of
sleeve faces front
and
flat side faces rear
(Fig. 153).
GEAR

SYNCHRO

SLEEVE

COUNTERSHAFT
FIFTH

GEAR

J9221-237

Fig.
153 Installing
Synchro
Sleeve
On
Countershaft
Fifth
Gear
Hub
(6) Install shift fork
in
synchro sleeve
(Fig. 154).

(7) Install assembled fifth gear, synchro sleeve
and

shift fork
(Fig. 155).
Align fork with shift
lug
rail and align gear with bearings
and
countershaft. Start

•
• release fork ball stud
• propeller shaft slip yoke

APPLY
LIGHT
COAT
OF

HI-TEMP
GREASE
TO
THESE

SURFACES
BEFORE
INSTALLATION
J9106-15

Fig.
18 input Shaft Lubrication
Points
(Typical)
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re­ lease bearing and clutch disc hub. Rotate output
shaft with socket or yoke to align input shaft and
clutch disc splines if necessary.
(4) Move transmission forward and seat transmis­
sion against housing. (5) Install and tighten transmission mounting
bolts to 68 N-m (50 ft-lbs). (6) Install rear crossmember and crossmember
brackets. Start all crossmember bolts/nuts before
tightening to final torque of 68 N»m (50 ft-lbs). (7) Remove transmission jack.
(8) Install screws that attach fuel line clamps to
driver side frame rail. (9) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (10) Install clutch slave cylinder shield.
(11) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(12) Align and install propeller shaft. Support
shaft on box or stand. Install shaft front U-joint first.
Next, secure center bearing bracket to frame bracket.
Then install shaft rear U-joint in axle yoke. Final- tighten U-joint clamp bolts to 19 N@m (14 ft-lbs) and center bearing bracket bolts to 68 N»m (50 ft-lbs). (13) Lower vehicle.
(14) Lubricate shift lever ball and collar with Mo­
par all purpose grease. (15) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (16) Press shift lever and collar downward and in­
stall shift lever snap ring. (17) Tighten shift lever alignment bolts com­
pletely. (18) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (19) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large G360
MANUAL TRANSMISSION
21 - 51

SKID

PLATE
J9121-525

Fig.
19 Transfer
Case
Skid
Plate
Mounting
notch is forward then install lower boot attaching
screws. (20) Thread or bolt shift lever extension to shift le­
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws.
(21) Install shift knob on extension (if removed). (22) Connect battery negative cable.

TRANSMISSION REMOVAL—4-WHEEL DRIVE
(1) Disconnect battery negative cable.
(2) Remove screws attaching shift lever upper boot
to metal plate on lower boot. Then slide boot upward on lever (Fig. 3).
(3) Remove screws attaching lower boot and plate
assembly to floor pan (Fig. 4). (4) Remove shift lever extension by unthreading it
from shift lever (Fig. 5). (5) Slide lower boot and plate upward and off shift
lever (Fig. 6). (6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).

(7)
Remove snap ring securing shift lever in shift
tower (Fig. 8). (8) Remove shift lever (Fig. 9). If lever does not
come out readily, press lever downward and quickly
release it two or three times. Pressure from spring under lever should push it out of housing. Note alignment slots in lever cover and pivot ball
(Fig. 9). These slots align with shoulder bolts in
shift tower.
(9) Raise and support vehicle.
(10) Mark front and rear propeller shafts for in­
stallation reference (Fig. 10). Then disconnect and re­
move both shafts. (11) Remove transfer case skid plate and cross-
member (Fig. 19).

21 - 52 G360
MANUAL
TRANSMISSION

• (12) Disconnect wires at vehicle speed sensor and
backup light switch.
(13) Disconnect transfer case shift lever from lever
on transfer case.
(14) Temporarily support transmission with adjust­
able jack stand. Then support transfer case with
transmission jack.
(15) Remove nuts attaching transfer case to trans­
mission adapter and move transfer case away from
transmission rear retainer.
(16) Lower transfer case and move it from under
vehicle. Remove transfer case from transmission jack and place transfer case on workbench.
(17) Support transmission with transmission jack.
Secure transmission to jack with safety chains. Then
remove jack stand previously used to support trans­
mission.
(18) Spread clamps that secure switch wires to
transmission top cover and remove wires from clamps. Move wires aside to protect them and pro­
vide working clearance.
(19) Remove bolts attaching transmission rear
mount to crossmember.
(20) On some models, it is necessary to remove
screws attaching fuel line clamps to driver side
frame rail. Three clamps must be removed to so fuel lines can be moved for access to crossmember bolts at
this side of frame rail.
(21) Remove left and right crossmember-to-frame
braces and remove crossmember.
(22) Remove clutch slave cylinder shield.
(23) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever (Fig.

20).
This reduces pressure on lever and release bear­
ing making transmission removal/installation easier. Cylinder does not have to be removed completely.
(24) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission slightly to help free input shaft from clutch disc and
release bearing.
(25) Support engine with wood block and another
adjustable jack stand.

TRANSMISSION
INSTALLATION—4-WHEEL
DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains.
(2) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of input shaft (Fig. 20) and following components:

CAUTION:
Do not use
excessive
amounts
of
grease.

This
practice
could
result in contamination of the

clutch
disc.

• input shaft splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bushing
• release bearing bore
• release fork
• release fork ball stud • propeller shaft slip yoke
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re­ lease bearing and hub of clutch disc. (4) Rotate output shaft with socket or yoke to align
input shaft and clutch disc splines. If input shaft will
not rotate enough in neutral to align splines, it will
be necessary to shift transmission into third or fourth gear with screwdriver. (5) Seat transmission against clutch housing and
align bolt holes in transmission and housing. (6) Install and tighten transmission-to-clutch hous­
ing bolts to 68 N-m (50 ft. lbs.). (7) Install rear crossmember and mount. Start all
crossmember bolts/nuts then tighten them to 68 N*m (50 ft. lbs.) torque. (8) Remove transmission jack.
(9) Install screws that attach fuel line clamps to
driver side frame rail. (10) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (11) Install clutch slave cylinder shield.
(12) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(13) Install gasket and transfer case on transmis­
sion rear retainer. Tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque. (14) Check transmission and transfer case lubri­
cant levels. Add lubricant if necessary and install fill

plugs.

(15) Connect transfer case shift lever to lever on
transfer case.
(16) Align and install propeller shafts. Tighten
U-joint clamp bolts to 19 N-m (14 ft. lbs.). (17) Install skid plate and crossmember. Tighten
skid plate and crossmember bolts/nuts to 41 N—m
(30 ft. lbs.) torque.
(18) Lower vehicle.
(19) Shift transmission into neutral if necessary.
(20) Lubricate shift lever ball and collar with Mo­
par all purpose grease. (21) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (22) Press shift lever and collar downward and in­
stall shift lever snap ring. (23) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (24) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large
notch is forward then install lower boot attaching screws. (25) Thread or bolt shift lever extension to shift le­
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws. (26) Install shift knob on extension (if removed).
(27) Connect battery negative cable.

•

G360
TRANSMISSION OVERHAUL
21 - 53
G360
TRANSMISSION
OVERHAUL

INDEX

page

Transmission
Assembly
and
Adjustment
.......
63

Transmission
Cleaning
and
Inspection
59

TRANSMISSION
DISASSEMBLY

SHIFT COVER REMOVAL (1) Shift transmission into neutral.
(2) Remove shift cover bolts.
(3) Loosen shift cover with
two pry
tools. Insert
tools
in
cover slots
and pry
cover
off
alignment dow­ els
(Fig. 1). It is
important
to
remove
the
cover evenly
to
avoid damage.
Do not pry one
side
loose then
the
other. This practice could damage the forks
and
cover.

SHIFT

COVER

Fig.
1
Loosening
Shift
Cover

(4) Remove shift cover assembly
(Fig. 2).
Discard
old shift cover gasket. Note that
a
gasket
was not

used
on
early production transmissions.
It is

recommended that
a
gasket
be
used when shift
cover
is
installed after overhaul. (5)
Set
shift cover assembly aside
for
inspection.

REARING
RETAINER
AND
SHAFT BEARING

RACE
REMOVAL (1) Remove front bearing retainer bolts
and re­

move retainer
(Fig. 3). Tap
retainer with rubber mal­ let
to
loosen
it if
necessary.
(2)
On
2-wheel drive models, remove rear bearing
retainer
as
follows
(Fig. 4):
(a) Remove
nut
attaching yoke
to
output.
Torque
on nut is
quite high. Best
way to re­

move
nut is
with 350-400
ft. lb.
rated high
ca­

pacity impact wrench.
(b) Remove yoke from output shaft splines.
page

Transmission
Disassembly
53

Fig.
2
Shift
Cover
Removal/Installation

CHANNELS
(4)
J9321-268
Fig.
3
Front Bearing Retainer
Removal

(c) Remove bolts attaching rear bearing retainer
to gear case
and
remove retainer.
Use
rubber mal­ let
to
loosen retainer
if
necessary.
(d) Remove speedometer gear
and
spacers from
output shaft.
(e) Remove preload shims from rear retainer,
or

bearings.
(f) Remove yoke seal from retainer with suitable
pry tool.
Do not
damage retainer surface while
re­
moving seal.
(3)
On
4-wheel drive transmission, remove rear
bearing retainer bolts
and
remove retainer from gear case
(Fig. 5).

•

G360
TRANSMISSION OVERHAUL
21 - 71
DEPTH
GAUGE
REAR
RETAINER COUNTERSHAFT
BEARING SHIM
BORE

J9321-332

Fig.
68
Measuring
Depth Of Countershaft Bearing
Shim
Bore
(in Rear
Retainer)
(5) Select preload shims for shaft bearings as fol­

lows:
Subtract height of bearing from depth of shim

bore.
Then add extra shim thickness of 0.15 - 0.20 mm ( 0.006 - 0.008 in.) for correct preload.
(6) Assemble and install shim packs in rear re­
tainer (Fig. 69). Use petroleum jelly to hold shim
packs in place during installation. Position thin shims at rear of pack where they will seat in
rear retainer shim bore.
TRANSMISSION FINAL ASSEMBLY (1) Apply Mopar Gasket Maker, or Loctite 518 to
rear retainer flange surface. OUTPUT
SHAFT
BEARING SHIMS
COUNTERSHAFT BEARING SHIMS REAR
RETAINER

J9321-325

Fig.
69 Preload
Shim
Location (2) On 2-wheel drive transmissions, install new
output shaft seal in retainer. Then install speedome­
ter gear and spacers on output shaft (Fig. 70).
(3) Install rear retainer on gear case. Do not dis­
place preload shims when installing retainer. (4) Apply Mopar or Loctite thread locker to rear
retainer bolts. Then install and tighten bolts to 22-30 N-m (16-22 ft. lbs.) torque.
(5) On 2-wheel drive transmissions, lube propeller
shaft yoke seal surface with petroleum jelly or en­
gine oil and install yoke. Then install and tighten
new yoke nut to 380 N*m (280 ft. lbs.) torque.
(6) Apply coat of Mopar Perfect Seal, or similar
sealer to new shift cover gasket. Then position gas­
ket on gear case. (Although early production trans- REAR
BEARING
RETAINER
SPEEDOMETER GEAR YOKE
NUT
YOKE
SPACERS

Fig.
70 Two
Wheel
Drive Rear Bearing Retainer And Speedometer Gear
J9321-271

•
Fig. 138 installing Accumulator Piston And Spring—32RH
(53) Position valve body on case. Work park rod
past sprag and install valve body-to-case bolts finger tight.
(54) Install neutral switch in case. Tighten switch
to 34 N-m (25 ft. lbs.) torque.
(55) Align valve body on case (Fig. 139). Tighten
valve body-to-case bolts alternately and evenly to 12
N»m (105 in. lbs.) torque. Start at center and work
outward when tightening bolts. Do not overtighten
valve body bolts. This could result in distortion and cross leakage after Installation..

VALVE

Fig. 139 Installing
Valve
Body—32RH
—
TRANSMISSION
OVERHAUL—32RH
21 - 1S1 (56) Install new filter on valve body. Tighten filter
screws to 4 N»m (35 in. lbs.).
(57) Position new extension housing gasket on
transmission case. Use petroleum jelly to hold gasket in place.
(58) Install rear bearing and snap ring on output
shaft. (59) Install extension housing on transmission
case. Tighten housing fasteners to 33 N»m (24 ft.

lbs.).
Be sure park lock rod is properly engaged in sprag before tightening fasteners.
(60) Adjust front/rear bands as follows: (a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 N*m (72

in.
lbs.).
(c) Back off front band adjusting screw 2-1/2
turns and rear band adjusting screw 4 turns.
(d) Hold each adjusting screw in position and
tighten locknuts to 34 N*m (25 ft. lbs.).
(61) Install new pan gasket on transmission and
install oil pan. Tighten pan bolts to 17 N«m (13 ft.

lbs.).
(62) Turn transmission over.
(63) Install new manual lever shaft seal in case.
Use 15/16 deep well socket to install seal.
(64) Install throttle valve and manual valve levers
on shaft. (65) Lubricate converter hub with transmission
fluid and carefully install converter. Turn converter
back and forth until seated. Be sure converter hub slots are fully seated in oil pump gear lugs.
(66) Secure converter in oil pump before mounting
transmission on jack and before moving transmission
back under vehicle. Use metal strapping or small C-clamp to hold converter in place. Attach strapping
or clamp to converter housing.

CAUTION:
The
transmission
cooler
and
lines
must
be
reverse
flushed
if
overhaul
corrected
a
malfunc­

tion that
generated
sludge,
metal
particles,
or
clutch
friction
material.
The
torque
converter
should

also
be
replaced
if
contaminated
by the
same
mal­

function.
Debris
and
residue
not
flushed
from
the
cooler
and
lines
will
flow
back
into the
transmission

and
converter.
The
result
could
be a
repeat
failure

and
shop
comeback.