Dodge ram truck 3500 1996 Service Manual page 1402

21 - 12 NV3500 MANUAL TRANSMISSION BR
DISASSEMBLY
A N D
ASSEMBLY
( C o n t i n u e d )
SHIFT SHAFT, SHIFT FORKS AMD REVERSE
IDLER SEGMENT REMOVAL
(1) Place shop towel over shaft lever and bushing
to contain lever detent ball and spring. Then rotate
lever and bushing upward out of shift forks and
catch ball and spring as they exit shaft lever (Fig.
24).
Fig. 24 Removing Shift Shaft Lever Detent Ball And
Spring
(2) Unseat roll pin that secures shift socket to
shift shaft with Special Tool 6858 as follows:
(a) Position Tool 6858 on shift socket. Then cen­
ter tool over roll pin. Be sure tool legs are firmly
seated on shift socket (Fig. 25).
(b) Tilt socket toward passenger side of case.
This places roll pin at slight angle to avoid trap­
ping pin between gear teeth.
(c) Tighten tool punch to press roll pin down­
ward and out of shift socket (Fig. 25). Roll pin does
not have to come completely out of shift shaft; it
only has to clear shift socket.
(d) If roll pin accidentally becomes jammed
between gear teeth locking socket and shaft
in place, proceed to alternate disassembly
method in next step.
(3) If shift socket roll pin becomes jammed,
alternate disassembly method is as follows:
(a) Remove rear bearing retainer bolts.
(b) Remove reverse idler segment (but leave gear
in case).
(c) Remove input shaft, bearing, and 3-4 synchro
ring.
Fig. 25 Unseating Shift Socket Roll Pin With Tool
6858
(d) Remove 3-4 shift fork and 3-4 synchro sleeve
simultaneously. Use shop rag to catch struts, balls,
and springs as sleeve comes off hub.
(e) Slide shift shaft bushing off shaft lever. Then
rotate lever out of shift fork arms and catch ball
and spring as lever clears notches.
(f) Push shift shaft rearward, tap out pin (if
needed) and pull shaft out of rear housing and
shift forks. Use plastic mallet to assist shaft
removal.
(4) Drive out roll pin that secures shift bushing
and lever to shift shaft (Fig. 26).
Fig. 26 Removing Shift Shaft Lever And Bushing
Roil Pin