Dodge RAM TRUCK 1500 1995 Service Manual page 1308

B R NV3500 MANUAL TRANSMISSION 21 - 25
it in place. A small flat blade screwdriver can be used
to press the ball into place while moving the sleeve
over it.
. (5) Eepeat the procedure for the remaining
springs, struts and balls. Tape, or a rubber band can
be used to temporarily secure each strut and ball as
they are installed.
(6) Verify synchro assembly. Be sure the three
springs, struts and detent balls are all in place (Fig.
57).
SLEEVE
HUB
SHOULDER
SPRING (3)
STRUT (3)
DETENT
BALL (3)
J9421-57
Fig. 57 Assembled View Of Synchro Components
OUTPUT SHAFT AND GEARTRAIN ASSEMBLY
Because the synchro hubs and rear bearing must
be pressed onto the output shaft, it is easier (and
faster), to assemble the entire geartrain while
mounted in a shop press. This method of reassembly
is demonstrated in the following procedure.
Two versions of the NV3500 are used in 1995
models. If any gears have been replaced, com­
pare them to the new parts before installation
to ensure a proper match. The original and new
versions have different ratio first and second
gears.
(1) Lubricate shaft, gears and bearings (Fig. 56)
with recommended lubricant during assembly. Petro­
leum jelly can be used to hold parts in place.
(2) Check bearing surfaces of output shaft for nicks
or scratches. Smooth surfaces with 320/400 grit em­
ery cloth if necessary. Apply oil to emery cloth and
shaft surface before polishing.
(3) Inspect and replace any synchro ring that ex­
hibits wear or damage. Completely immerse each
synchro ring in lubricant before installation.
(4) Recheck needle bearings once again before as­
sembly, replace any bearing exhibiting wear, or dam­
age to the bearing rollers or plastic bearing cage.
Petroleum jelly can be used to prelubricate bearings
if desired.
(5) Lubricate and install reverse gear needle bear­
ing on shaft (Fig. 58). Slide bearing up against shoul­
der on output shaft as shown.
REVERSE
GEAR
BEARING
SHOULDER
J9421-58
Fig. 58 Reverse Gear Bearing Installation
(6) Install reverse gear over needle bearing (Fig.
59).
REVERSE
GEAR
J9421-59
Fig. 59 Reverse Gear Installation
(7) Install solid brass synchro ring on reverse gear
(Fig.
60).
SYNCHRO
RING
(SOLID BRASS)
REVERSE
GEAR
J9421-60
Fig. 60 Reverse Gear Synchro Ring Installation
(8) Assemble fifth-reverse synchro hub, sleeve,
struts, springs and detent balls, if not previously
done.