Dodge Dakota Sport 2001 Service Manual page 1418

AN
MANUAL - NV1500 (Continued)
GEARTRAIN
(1) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(2) Separate countershaft from mainshaft.
(3) Separate input shaft from output shaft.
COUNTERSHAFT
(1) Remove countershaft front and rear bearing
with Puller 8356.
(2) Remove rear bearing race (in rear housing)
with Bearing Race Remover L-4454. Install new race
with Driver C-4656 and Driver Handle C-4171.
(3) Remove bearing shim cap from front housing
(below input shaft bearing retainer). Remove shim.
Drive race through and out of housing with Driver
C-4656 and Driver Handle C-4171. Install new race
into housing from outside. Do not drive all the
way into position. Tightening the shim cap will
install the race to the proper position. Install
shim and shim cap and torque cap bolts to 28.5 N·m
(21 ft. lbs.).
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different.
Remove synchronizer unit as an assembly to avoid
intermixing parts. Mark each synchro hub and
sleeve for assembly reference.
(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembly, third gear syn-
chro ring and third gear with a shop press and Split-
ter 1130. Position splitter between second and third
gears.
(3) Remove third gear needle bearing (Fig. 22).
Fig. 22 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
(4) Remove retaining ring that secures two-piece
thrust washer on shaft.
(5) Remove two-piece thrust washer (Fig. 23). Note
position of washer locating lugs in shaft notches for
installation reference.
Fig. 23 TWO-PIECE THRUST WASH
1 - WASHER (2 HALVES)
2 - PIN RELIEF
3 - PIN
(6) Remove second gear and needle bearing (Fig.
24).
Fig. 24 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
(7) Remove 2nd-3rd gear thrust washer locating
pin.
(8) Remove second gear synchro ring and synchro
cone.
(9) Remove 1-2 synchro hub snap ring.
MANUAL - NV1500 21 - 9