Dodge ram truck 3500 1996 Service Manual page 1412

21 - 22 NV3500 MANUAL TRANSMISSION B R
DISASSEMBLY AND ASSEMBLY (Continued)
SYNCHRO C01P0NENT ASSEMBLY
The easiest method of assembling each synchro is
to install the springs, struts and detent balls one at a
time as follows:
(1) Slide the sleeve part way onto the hub. Leave
enough room to install the spring in the hub and the
strut in the hub groove.
(2) Install the first spring in the hub. Then install
a strut over the spring. Be sure the spring is seated
in the spring bore in the strut.
(3) Slide the sleeve onto the hub just far enough to
hold the first strut and spring in place.
(4) Place the detent ball in the top of the strut.
Then carefully work the sleeve over the ball to hold
it in place. A small flat blade screwdriver can be used
to press the ball into place while moving the sleeve
over it.
(5) Repeat 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.
64).
SLEEVE
H U l
SHOULDER
SPRING (3)
I
STRUT (3)
DETENT
BALL (3)
J9421-57
Fig. 64 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 ver­
sions of the NV3500 are used. If any gears have
been replaced, compare 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 with rec­
ommended lubricant during assembly. Petroleum
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
emery cloth i f necessary. Apply oil to emery cloth and
shaft surface before polishing.
(3) Inspect and replace any synchro ring that
exhibits wear or damage. Completely immerse each
synchro ring in lubricant before installation.
(4) Recheck needle bearings once again before
assembly, replace any bearing exhibiting wear, or
damage 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. 65). Slide bearing up against shoul­
der on output shaft as shown.
REVERSE
GEAR
BEARING
SHOULDER
J9421-58
Fig. 65 Reverse Gear Bearing Installation
(6) Install reverse gear over needle bearing (Fig.
66).
REVERSE
GEAR
Fig. 66 Reverse Gear Installation