Dodge RAM TRUCK 1500 1995 Service Manual page 1304

B R — — — — — NV3500 MANUAL TRANSMISSION 21 - 21
SHIFT
! SHAFT
SHAFT
LEVER
SHAFT
LEVER
BUSHING
FIFTH-REVERSE SHIFT
FORK
1-2 SHIFT
FORK
3-4 SHIFT
FORK
J9421-54
Fig. 53 Shift Forks And Shaft
Check condition of the oil tube in the rear housing.
The tube must not be bent or loose. The housing will
have to be replaced if the tube is loose or damaged.
Pay particular attention to the bushings and
bearings in the front and rear housings. The
front housing contains the shift shaft front
bearing and bushing, the countershaft front
bearing race and the detent plunger bushing.
The r e a r housing contains the shift shaft r e a r
bushing and t h e countershaft rear bearing
race. Be advised that these components are
NOT serviceable items. The front housing will
have to be replaced if the shift shaft bearing
and bushing, detent plunger bushing, or coun­
tershaft bearing race is loose, worn, or dam­
aged. The rear housing will have to be replaced
if the shift shaft rear bushing, or the counter­
shaft rear bearing race is loose, worn, or dam­
aged.
Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth and final
polished with oil coated crocus cloth. Replace the re­
tainer seal if necessary.
Inspect the output shaft bearing retainer. Be sure
the U-shaped retainer is flat and free of distortion.
Replace the retainer if the threads are damaged, or if
the retainer is bent, or cracked.
Countershaft Bearings And Races
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a
bearing race becomes damaged, it will be nec­
essary to replace the front or rear housing as
necessary. In addition, if a countershaft bearing
becomes damaged, it will be necessary to re­
place not only the bearing but the applicable
housing as well. A new countershaft bearing
will be supplied with each new housing for ser­
vice use.
The countershaft bearings can be installed back­
wards if care is not exercised. The bearing roller cage
is - a different diameter on each side. Be sure the
bearing is installed so the large diameter side
of the cage is facing the countershaft gear (Fig.
54). The small diameter side goes in the bearing
race.
Reverse Idler Components
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate (Fig. 52). Re­
place the bearing if any of the needle bearing rollers
are worn, chipped, cracked, flat-spotted, or brin-
nelled. Also replace the bearing if the plastic bearing
cage is damaged or distorted.
Replace the thrust washer, wave washer, or thrust
plate if cracked, chipped, or worn. Replace the idler
gear if the teeth are chipped, cracked or worn thin.
Replace the shaft if worn, scored, or the bolt threads
are damaged beyond repair. Replace the support seg­
ment if cracked, or chipped and replace the idler at­
taching bolts if the threads are damaged.