Dodge ram truck 3500 1996 Service Manual page 1442

21 - 1 2 NV4500 MANUAL TRANSMISSION B R
DIAGNOSIS AND TESTING fContinued)
shifting. Any of the foregoing faults will cause com­
ponent bind and high shift efforts.
Misassembled synchro components will also cause
shift problems. Incorrectly installed synchro sleeves,
struts, or springs will all cause shift problems.
NOISY OPERATION
Transmission noise is most often a result of worn
or damaged components. Chipped, broken gear or
synchronizer teeth and brinnelled, spalled bearings
all cause noise.
Abnormal wear and damage to internal compo­
nents is frequently the end result of insufficient
lubricant, non-recommended lubricants, or improper
operation.
SLIPS OUT OF GEAR
Transmission disengagement may be caused by
misaligned or damaged shift components, or worn
teeth on the mainshaft gears or synchro components.
Incorrect assembly will also contribute to gear disen­
gagement.
LOW LUBRICANT LEVEL
Insufficient transmission lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method.
Leaks will be evident by the presence of gear oil
around the leak point. I f leakage is not evident, the
condition is probably the result of an under fill con­
dition.
If air powered lubrication equipment is used to fill
a transmission, be sure the equipment is properly
calibrated. Equipment out of calibration can lead to
an underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
A damaged pilot bearing will cause noise. I f bear­
ing damage is severe, drive gear misalignment and
hard shifting can also occur.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
Damaged or worn clutch hydraulic components, or
leaks in the fluid lines or cylinders will cause hard
shifting and gear clash. Failure of one of the clutch
hydraulic cylinders can result in incomplete clutch
release or engagement.
Verify that clutch components are all in good con­
dition before removing the transmission for repair.
S E R V I C E P R O C E D U R E S
SHIFT COVER COMPONENTS
The only serviceable shift cover components are:
• fifth-reverse shift fork pads
© reverse inhibitor
• vent components
• backup light switch
• expansion plugs
• shift lever components
The shift cover, shift forks, shift rails and detent
components are not serviced individually. The cover
must be replaced as an assembly i f the cover, or any
shift components are worn or damaged.
SHIFT COWER INSPECTION
Inspect the cover and shift components whenever
the cover is removed from the gear case. Or, when­
ever diagnosis indicates inspection is necessary.
Check the forks for wear, distortion, cracks, or
being loose on the shift rails. Also check fit of the
shift rails in the cover. Replace the cover assembly i f
the rails are loose in the cover bores.
Inspect and replace the pads on the fifth-reverse
shift fork i f worn. The reverse inhibitor should also
be replaced i f worn, or faulty. The expansion plugs at
the rear of the cover can be replaced i f loose or leak­
ing.
A gasket is not used between the shift cover
and gear ease. Use Mopar Gasket Maker, or
Loctite 518 to seal the cover.
Procedures for the serviceable components in the
shift cover as follows:
FIFTM-REWEMSE SHIFT FORK PAD
REPLACEMENT
The plastic shift fork pads are held in place by a
combination of tension and a small locating tang.
Three pads are used on the fork (Fig. 5).
The pads can be removed either by hand or with a
narrow blade screwdriver. To remove the pads by
hand, grasp each pad and tilt i t out and off the fork.
I f the pads prove difficult to remove by hand, insert a
screwdriver blade between the pad and fork and pry
the pad off.
REVERSE INHIBITOR REPLACEMENT
The reverse inhibitor mechanism should be
checked for wear or damage whenever diagnosis indi­
cates this is necessary.
The inhibitor mechanism is attached to the cover
with two screws (Fig. 6). Attaching screw torque is
8-14 N-m (75-115 in. lbs.).