Dodge RAM TRUCK 1500 1995 Service Manual page 1303

21 - 20 NV3500 MANUAL TRANSMISSION
B R
SNAP
RING
PLAT
WASHER
WAVE
WASHER
THRUST
WASHER
REVERSE
IDLER
GEAR
IDLER
GEAR
BEARING
IDLER
SHAFT
I) j
, " 5
V
THRUST
WASHER
LOCK BALLS
THRUST SNAP
WASHER RING
J9421-53
Fig. 52 Reverse
n e v e n s e
IDLEM DISASSEMBLY
f
F I G *
S 2 j
(1) Remove idler gear snap rings.
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
TRANSMISSION COMPONENT CLEANING ANO
INSPECTION
Repair Parts Ordering
Two versions of the NV3500 are now avail­
able. The wide ratio version introduced last
year, has 4.01 first gear and a 2.318 second gear.
The new close ratio version has a 3.49 first gear
and 2.16 second gear. Since the two transmis­
sion versions are virtually identical in appear­
ance, it is very important that the transmission
assembly part number be available when order­
ing repair parts. The assembly number is on a
sticker, or plate attached to the gear case.
Component Cleaning
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean­
ing solvent. Do not use acid or corrosive base sol­
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk, or similar sol­
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry, or wipe them dry
with clean shop towels.
Shift Lever Assembly
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball, or internal components are worn, or
damaged.
er Components
Shift Shaft And Forks
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 53). Replace any fork ex­
hibiting wear or damage in these areas. Do not at­
tempt to salvage shift forks.
Inspect the shift shaft bushings and front
bearing carefully. The bushings and bearing are
not serviceable items. The front or rear housing
will have to be replaced if these components
are damaged in any way.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks, or scores. The plunger spring should be
straight and hot collapsed, or distorted. Minor
scratches, or nicks on the plunger can be smoothed
with 320/400 grit emery soaked in oil. Replace the
plunger and spring if in doubt about condition.
Inspect the shift shaft, the shaft lever and the le­
ver bushing that fits over the lever. Replace the shaft
if bent, cracked, or severely scored. Minor burrs,
nicks, or scratches can be smoothed off with 320/400
grit emery cloth followed by polishing with crocus
cloth.
Replace the shaft lever and bushing if either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the
small detent ball and spring that goes in the lever if
the ball is worn, or if the spring is bent or collapsed.
Replace the roll pin that secures the lever to the
shaft.
Front/Rear Housings And Bearing Retainers
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores, or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file,
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.