Dodge Dakota Sport 2001 Service Manual page 1412

AN
MANUAL - NV1500 (Continued)
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non–recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab, and/or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper, or contaminated lubricants. The con-
sequence of using non–recommended lubricants is
noise, excessive wear, internal bind, and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment,
or a damaged clutch pressure plate or disc are addi-
tional probable causes of increased shift effort. Incor-
rect adjustment or a worn/damaged pressure plate or
disc can cause incorrect release. If the clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear–
in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe, highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper, or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove floor console. Refer to 23 Body for pro-
cedures.
(4) Remove screws attaching shift boot to floorpan.
Then slide boot upward on lever extension.
(5) Remove shift lever extension from the shift
tower and lever assembly.
(6) Raise and support vehicle.
(7) Mark propeller shaft and axle companion
flange for alignment reference. Use paint, scriber, or
chalk to mark flange.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system Y-pipe.
(10) Disconnect wires at backup light switch.
(11) Support engine with adjustable safety stand
and wood block.
(12) If transmission is to be disassembled for
repair, remove drain plug and drain lubricant from
transmission.
(13) Remove bolts/nuts attaching transmission to
rear mount.
(14) Support transmission with a transmission
jack. Secure transmission to jack with safety chains.
(15) Remove rear crossmember.
(16) Remove bolts attaching clutch slave cylinder
to clutch housing. Then move cylinder aside for work-
ing clearance.
(17) Remove starter.
(18) Remove transmission dust shield.
(19) Remove transmission harness wires from clips
on transmission shift cover.
(20) Lower transmission slightly.
(21) Remove the bolts attaching the shift tower
and lever assembly to the transmission housing.
Then remove the shift tower and lever assembly.
(22) Remove bolts
engine.
(23) Slide transmission and jack rearward until
input shaft clears clutch disc.
(24) Lower transmission jack and remove trans-
mission from under vehicle.
DISASSEMBLY
FRONT HOUSING
(1) Shift transmission into Neutral.
(2) Remove drain plug and drain lubricant into a
container.
(3) Inspect drain plug magnet for debris.
(4) Remove backup light switch (Fig. 2).
(5) Remove shift tower bolts and remove tower and
lever assembly (Fig. 3).
MANUAL - NV1500
attaching transmission
21 - 3
to