Page 1665 of 2889
(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. 86).(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
87). Arm of fifth-reverse fork goes through slot in 1-2
fork.
(13) Install assembled shift forks in synchro
sleeves and verify forks are seated in sleeves (Fig.
88).
Fig. 85 Reverse Idler Assembly On Assembly
Fixture Tool
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - TOOL PEDESTAL
Fig. 86 Positioning Output Shaft Bearing Retainer
1 - PIN 8120
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 87 1-2 And Fifth-Reverse Shift Forks
1 - INSERT ARM THROUGH 1-2 FORK
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
Fig. 88 Shift Forks In Synchro
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
21 - 30 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)
Page 1666 of 2889

REAR HOUSING - 2WD
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 89).
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 90).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 91).
(4) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 91).
(6) Reach into countershaft rear bearing with fin-
ger and push each bearing roller outward against the
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
Fig. 89 Rear Housing Dowels
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
Fig. 90 Countershaft Rear
1 - COUNTERSHAFT REAR BEARING
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY (APPLY TO BEARING AND RACE)
Fig. 91 Countershaft Bearing
1 - SHIFT SHAFT BUSHING/BEARING
2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE)
BR/BEMANUAL - NV3500 21 - 31
MANUAL - NV3500 (Continued)
Page 1667 of 2889

(7) Install rear housing onto geartrain (Fig. 92)
and verify bearing retainer pilot stud is in correct
bolt hole in housing. Be sure countershaft and output
shaft bearings are aligned in housing and on counter-
shaft.
NOTE: It may be necessary to lift upward on coun-
tershaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
(9) Apply Mopar Gasket Maker or equivalent to
housing bolt threads, bolt shanks and under bolt
heads (Fig. 93).
(10) Start first two bolts in retainer (Fig. 94). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 94).
(12) Tighten all three retainer bolts to 30-35 N´m
(22-26 ft. lbs.).
ADAPTER HOUSING - 4WD
(1) Install rear bearing in adapter housing. Use
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 95).
Fig. 92 Rear Housing - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 93 Housing Bolts
1 - MOPAR GASKET MAKER (OR LOCTITE 518)
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 94 Pilot Stud Tool And Retainer Bolts - 2WD
1 - BEARING RETAINER BOLT
2 - PIN 8120
21 - 32 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)
Page 1668 of 2889

(3) Apply Mopar Gasket Maker or equivalent to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 93).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 91).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 91).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 91).
(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 96).
(10) Lubricate lip of new rear seal (Fig. 97) with
MopartDoor Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 97).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify that all synchro sleeves are in Neutral
position (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position for reassembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
Fig. 95 Adapter Housing - 4WD
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
Fig. 96 Rear Bearing Snap Ring - 4WD
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 97 Rear Seal
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
BR/BEMANUAL - NV3500 21 - 33
MANUAL - NV3500 (Continued)
Page 1669 of 2889

(2) Install 3-4 shift fork in synchro sleeve (Fig. 98).
Verify groove in fork arm is aligned with grooves in
1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
99)with shaft detent notches to the rear.
(4) Assemble shift shaft shift lever and bushing
(Fig. 100). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 101).(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
102).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 103).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
Fig. 98 3-4 Shift Fork
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 99 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 100 Shift Shaft Lever And Bushing
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 101 Install Shift Shaft Lever And Bushing
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
21 - 34 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)
Page 1670 of 2889

CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-
mission will have to be disassembled again to cor-
rect shaft alignment.
(9) Select correctnewroll pin for shift shaft lever
(Fig. 104). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 105).(11) Seat shaft lever roll pin with pin punch (Fig.
106).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 106).
(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 107).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket after installation
(Fig. 108).
(15) Verify that notches in shift fork arms are
aligned. Realign arms if necessary.
Fig. 102 Inserting Shaft Into Lever Opening
1 - SHIFT SHAFT
Fig. 103 Shift Socket
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 104 Roll Pin Identification
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 105 Roll Pin In Shift Socket
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
BR/BEMANUAL - NV3500 21 - 35
MANUAL - NV3500 (Continued)
Page 1671 of 2889

FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) If previously removed, install input shaft bear-
ing in front housing bore (Fig. 109). Install snap ring
and use plastic mallet to seat bearing. Bearing goes
in from front side of housing only.
(2) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 109). Large diameter side of
bearing cage goes toward countershaft (Fig. 110).
Small diameter side goes toward bearing race in
housing.(3) Reach into countershaft front bearing with fin-
ger and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
Fig. 106 Shift Shaft Lever Roll
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 107 Roll Pin In Shift Socket
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 108 Seat Shift Socket
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
Fig. 109 Input Shaft Bearing And Countershaft Front
Bearing
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
21 - 36 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)
Page 1672 of 2889

(5) Apply 1/8 in. wide bead of MopartGasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 111).
(6) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) 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.
(9) Place transmission in horizontal position.
(10) Apply MopartGasket Maker or equivalent, to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 112).
(11) Install and start housing attaching bolts by
hand (Fig. 112). Then tighten bolts to 34 N´m (25 ft.
lbs.).
(12) Install shift shaft bushing lock bolt (Fig. 113).
Apply Mopar Gasket Maker or equivalent to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubricate then install shift shaft detent
plunger in housing bore (Fig. 114). Lubricate plunger
with petroleum jelly or gear lubricant. Verify plunger
is fully seated in detent notch in shift shaft.
(14) Install detent spring inside plunger (Fig. 114).
(15) Install detent plug in end of Installer 8123.
Position plug on detent spring and compress spring
until detent plug pilots in detent plunger bore. Drive
detent plug into transmission case until plug seats.
(16) Install backup light switch (Fig. 115).
Fig. 110 Countershaft Front Bearing
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 111 Seal Front/Rear Housings
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 112 Housing Bolts
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
BR/BEMANUAL - NV3500 21 - 37
MANUAL - NV3500 (Continued)