Dodge Dakota Sport 2001 Service Manual page 1460

AN
MANUAL - NV3500 (Continued)
Shift Socket
Inspect the shift socket for wear or damage.
replace the socket if the roll pin, or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn, or cracked. Do not reuse the original
shift socket roll pin. Install a new pin during reas-
sembly. The socket roll pin is approximately is
approximately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all of the gears for worn, cracked, chipped,
or broken teeth. Also 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 the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-
aged or bearing surfaces are deeply scored, worn, or
brinnelled.
ASSEMBLY
Sealers are used at all case joints. Usa Mopar Gas-
ket Maker for all case joints and Mopar silicone
sealer or equivalent, for the input shaft bearing
retainer. Apply these products as indicated in the
assembly procedures.
CAUTION: The transmission shift components must
be in the Neutral position during assembly. This
prevents damage to the synchro and shift compo-
nents when the housings are installed.
SYNCHRONIZER
To assemble each synchro install the springs,
struts and detent balls one at a time as follows:
(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 the first spring in the hub. Then install
a strut over the spring. Be sure the 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 the detent ball in the top of the strut.
Then carefully 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.
MANUAL - NV3500
(5) Repeat the procedure
springs, struts and balls. Tape or rubber band each
strut and ball to temporarily secure as they are
installed.
(6) Verify synchro springs, struts and detent balls
are all in place (Fig. 52).
Fig. 52 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
OUTPUT SHAFT
Lubricate shaft, gears and bearings with recom-
mended lubricant during assembly. Petroleum jelly
can be used to hold parts in place. Check bearing
surfaces of output shaft for nicks or scratches.
Smooth surfaces with 320/400 grit emery cloth if nec-
essary. Apply oil to emery cloth and shaft surface
before polishing.
Inspect and replace any synchro ring if worn or
damage. Immerse each synchro ring in lubricant
before installation.
(1) Lubricate and install reverse gear needle bear-
ing on shaft (Fig. 53). Slide bearing up against shoul-
der on output shaft.
(2) Install reverse gear over needle bearing (Fig.
54).
(3) Install brass synchro ring on reverse gear (Fig.
55).
(4) Assemble fifth-reverse synchro hub, sleeve,
struts, springs and detent balls, if not previously
done.
21 - 51
for the remaining