Dodge ram truck 3500 1996 Service Manual page 1435

BR
NV3500 MANUAL TRANSMISSION 21 - 45
CLEANING AND INSPECTION
(Continued)
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks, or scores. The plunger spring should be
straight and not collapsed, or distorted. Minor
scratches, or nicks on the plunger can be smoothed
with 320/400 grit emery soaked in oil. Replace the
plunger and spring i f in doubt about condition.
Inspect the shift shaft, the shaft lever and the
lever bushing that fits over the lever. Replace the
shaft i f bent, cracked, or severely scored. Minor
burrs, nicks, or scratches can be smoothed off with
320/400 grit emery cloth followed by polishing with
crocus cloth.
Replace the shaft lever and bushing i f either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the
small detent ball and spring that goes in the lever i f
the ball is worn, or i f the spring is bent or collapsed.
Replace the roll pin that secures the lever to the
shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores, or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file,
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.
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 i f the tube is loose or damaged.
NOTE: 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 rear housing con­
tains the shift shaft rear bushing and the counter­
shaft 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
countershaft bearing race is loose, worn, or dam­
aged. The rear housing will have to be replaced if
the shift shaft rear bushing, or the countershaft rear
bearing race is loose, worn, or damaged.
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
retainer seal i f 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.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear­
ing race becomes damaged, it will be necessary to
replace the front or rear housing a s necessary. In
addition, if a countershaft bearing becomes dam­
aged, it will be necessary to replace not only the
bearing but the applicable housing a s well. A new
countershaft bearing will be supplied with each new
housing for service use.
The countershaft bearings can be installed back­
wards i f 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.
156). The small diameter side goes in the bear­
ing race.
COUNTERSHAFT
J9421-55
Fig. 156 Correct Countershaft Bearing Installation
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing i f any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted, or brinnelled. Also
replace the bearing i f the plastic bearing cage is
damaged or distorted.