Dodge dakota 2002 Service Manual page 1840

DR
TRANSMISSION AND TRANSFER CASE
MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV4500
MANUAL TRANSMISSION - NV5600
AUTOMATIC TRANSMISSION - 46RE
AUTOMATIC TRANSMISSION - 48RE
MANUAL TRANSMISSION - NV3500
MANUAL TRANSMISSION - NV3500
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MANUAL TRANSMISSION -
NV3500
DESCRIPTION
The transmission is a medium-duty 5-speed, con-
stant mesh fully synchronized manual transmission
with fifth gear overdrive range. The transmission is
available in two and four-wheel drive configurations.
The transmission gear case consists of two aluminum
housings (Fig. 1). The clutch housing is an integral
part of the transmission front housing.
A combination of roller and ball bearings are used
to support the transmission shafts in the two hous-
ings. The transmission gears all rotate on caged type
needle bearings. A roller bearing is used between the
input and output shaft.
The transmission has a single shaft shift mecha-
nism with three shift forks all mounted on the shaft.
The shaft is supported in the front and rear housings
by bushings and one linear ball bearing. Internal
shift components consist of the forks, shaft, shift
lever socket and detent components
OPERATION
The manual transmission receives power through the
clutch assembly from the engine. The clutch disc is
TABLE OF CONTENTS
page
. . . . . . . . . . 1
. . . . . . . . . . 42
. . . . . . . . . . 87
. . . . . . . . 129
. . . . . . . . 310
TABLE OF CONTENTS
page
. . . . . . . . . . . . . . . . 3
TRANSMISSION AND TRANSFER CASE
AUTOMATIC TRANSMISSION - 45RFE/545RFE
TRANSFER CASE - NV241 GENII
TRANSFER CASE - NV271
TRANSFER CASE - NV243
TRANSFER CASE - NV273
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 40
splined to the transmission input shaft and is turned at
engine speed at all times that the clutch is engaged.
The input shaft is connected to the transmission coun-
tershaft through the mesh of fourth speed gear on the
input shaft and the fourth countershaft gear. At this
point, all the transmission gears are spinning.
The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shift lever
moves the selected shift rail, the shift fork attached
to that rail begins to move. The fork is positioned in
a groove in the outer circumference of the synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer does
this by having the synchronizer hub splined to the
mainshaft and moving the blocker ring into contact
with the gear's friction cone. As the blocker ring and
friction cone come together, the gear speed is brought
up or down to the speed of the synchronizer. As the
two speeds match, the splines on the inside of the
synchronizer sleeve become aligned with the teeth on
the blocker ring and the friction cone and eventually
will slide over the teeth, locking the gear to the
mainshaft, or countershaft, through the synchronizer.
21 - 1
page
. . 488
. . . . . . . . . . . 591
. . . . . . . . . . . . . . . . 623
. . . . . . . . . . . . . . . . 658
. . . . . . . . . . . . . . . . 687
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