Dodge Dakota Sport 2001 Service Manual page 1422

AN
MANUAL - NV1500 (Continued)
are worn, chipped, cracked, flat-spotted or brinnelled.
Also replace the bearing if the plastic bearing cage is
damaged or distorted.
Fig. 34 REVERSE IDLER ASSEMBLY
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
Replace thrust washer, if cracked, chipped or worn.
Replace idler gear if the teeth are chipped, cracked or
worn thin. Replace shaft if worn, scored or the bolt
threads are damaged beyond repair. Replace support
segment if cracked or chipped and replace the idler
attaching bolts if the threads are damaged.
Shift Socket
Inspect shift socket for wear or damage. Replace
socket if the roll pin or shift shaft bores are dam-
aged. Minor nicks in the shift lever ball seat in the
socket can be smoothed down with 400 grit emery or
wet/dry paper. Replace socket if the ball seat is worn,
or cracked. Do not reuse the original shift socket roll
pin. The socket roll pin is approximately is approxi-
mately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro-
ken teeth. Check condition of the bearing bore in each
gear. The bores should be smooth and free of surface
damage. Discoloration of the gear bores is a normal
occurrence and is not a reason for replacement.
Replace gears only when tooth damage has occurred or
if the bores are brinnelled or severely scored.
Inspect shaft splines and bearings surfaces. Minor
nicks on the bearing surfaces can be smoothed with
320/420 grit emery and final polished with crocus
cloth. Replace the shaft if the splines are damaged or
bearing surfaces are deeply scored, worn or brinnelled.
MANUAL - NV1500
ASSEMBLY
SYNCHRONIZER
NOTE: The easiest method of assembling each syn-
chro is to install the springs, struts and detent balls
one at a time.
(1) Slide the sleeve part way onto the hub. Leave
enough room to install the spring in the hub and the
strut in the hub groove.
(2) Install first spring in the hub and then install
a strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide the sleeve onto the hub just far enough to
hold the first strut and spring in place.
(4) Place detent ball in the top of the strut. Then
work the sleeve over the ball to hold it in place. Use
a small flat blade screwdriver to press the ball into
place while moving the sleeve over it.
(5) Repeat procedure for the remaining springs,
struts and balls. Tape or rubber band each strut and
ball temporarily as they are installed.
(6) Verify the three springs, struts and detent balls
are all in place (Fig. 35).
Fig. 35 ASSEMBLED SYNCHRO COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
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