Dodge ram truck 3500 1996 Service Manual page 1394

21 - 4 NV3500 MANUAL TRANSMISSION — — — — — — — BR
D I A G N O S I S A N D T E S T I N G ( C o n t i n u e d )
CLOSE RATIO VERSION
RANGE RATIO
FIRST
3.49:1
SECOND
2.16:1
THIRD = 1.401:1
FOURTH = 1:1
FIFTH =
0.729:1
REVERSE
3.55:1
Leaks can occur at the mating surfaces of the
housings, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at component mating surfaces will probably
be the result of inadequate sealer, gaps i n the sealer,
incorrect bolt tightening, or use of a non-recom­
mended sealer.
A leak at the front of the transmission will be from
either a loose or damaged, front bearing retainer or
retainer seal. Lubricant may also drip from the
transmission clutch housing after extended opera­
tion. I f the leak is severe, it will contaminate the
clutch disc causing slip, grab and chatter.
Transmissions filled from air or electrically pow­
ered lubricant containers can be under filled. This
generally happens when the container delivery mech­
anism is improperly calibrated. Always check the
lubricant level after filling to avoid an under fill con­
dition.
A correct lubricant level check can only be
made when the vehicle is level; use a drive-on
hoist to ensure this. Also allow the lubricant to
settle for a minute or so before checking. These
recommendations will ensure an accurate
check and avoid an under-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, transmis­
sion component damage, clutch linkage malfunction,
or by a damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
component, synchro and bearing damage. I f a leak
goes undetected for an extended period, the first indi­
cations of a problem are usually hard shifting and
noise.
Incorrect or contaminated lubricants can also con­
tribute to hard shifting. The consequence of using
non-recommended lubricants is * noise, excessive
wear, internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. I f
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. I n some
new or rebuilt transmissions, new synchro rings may
tend to stick slightly causing stiff and/or noisy shifts.
In most cases, this condition will decline as the rings
wear in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur­
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi­
cient, improper, or contaminated lubricant can pro­
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
mmmmAL ^mm
I N S T A L L A T I ® N
TRANSMISSION—2WD
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove bolts attaching shift tower and lever
assembly to rear case. Then remove shift tower and
shift lever extension as assembly (Fig. 4).
(5) I f isolator and plate came off during shift tower
removal (Fig. 4), remove assembly from shift hous­
ing. Note that plate is one-way fit. Narrow side of
plate goes toward driver side of transmission.
Fig. 4 Shift Tower Removal
(6) Raise vehicle on hoist.
(7) Remove crankshaft position sensor. Retain sen­
sor attaching bolts.