Dodge D150 1990 Service Manual page 869

2 1 - 1 8 MANUAL TRANSMISSION
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ADAPTER AND PINION INSTALLATION
CAUTION: Before installing the pinion and adapter
assembly make sure the adapter flange and the
mating area in the extension housing are perfectly
clean. Dirt, sand, or foreign material will cause mis-
alignment resulting in speedometer pinion gear
damage.
(1) Thoroughly clean t h e adapter flange a n d
adapter m o u n t i n g surface i n t h e extension housing.
These surfaces m u s t be clean for proper adapter
alignment a n d speedometer operation.
(2) I n s t a l l a new O - r i n g on t h e adapter.
(3) Lubricate the adapter o i l seal and O-ring w i t h
transmission fluid.
(4) Count t h e number o f teeth on the p i n i o n gear
and i n s t a l l t h e gear i n t h e adapter. Be sure to count
the gear teeth b e f o r e i n s t a l l i n g the gear.
(5) Note t h e range numbers o n the adapter face
(Fig. 4). These numbers correspond to the number o f
teeth on the speedometer p i n i o n gear.
(6) Insert the adapter i n the extension housing.
(7) Rotate t h e adapter u n t i l t h e required range
numbers are a t a six o-clock position (Fig. 4). Be sure
the adapter range numbers correspond to t h e number
of teeth on the p i n i o n .
(8) L i g h t l y push the adapter a l l the w a y into the
extension housing.
(9) I n s t a l l t h e adapter retainer. T i g h t e n t h e r e -
t a i n e r bolt t o 100 in-lbs (11 N-m) torque.
(10) I n s t a l l t h e distance sensor on t h e adapter.
T i g h t e n the sensor coupling n u t . to 150 in-lbs (17
N-m) torque and i n s t a l l t h e sensor wires.
(11) Check and top o f f t h e transmission l u b r i c a n t
level i f necessary.
Fig. 4 Indexing Speedometer Adapter
EXTENSION HOUSING YOKE SEAL REPLACEMENT
(1) Raise the vehicle a n d position a d r a i n pan u n -
der the extension housing.
(2) M a r k position o f t h e propeller shaft and rear
axle yokes for alignment reference.
(3) Disconnect t h e propeller shaft a t the axle yoke
and remove t h e shaft.
(4) Remove t h e o i l seal w i t h tool C-3985 { F i g . 5).
(5) I n s t a l l t h e new seal w i t h tool C-3972 (Fig. 6).
S t a r t the seal i n t h e housing and tap i t i n t o place
u n t i l t h e tool bottoms against the housing.
(6) Check condition o f the slip yoke surface o f t h e
propeller shaft. Reduce m i n o r corrosion, scratches, or
nicks w i t h crocus cloth or 400 g r i t sandpaper. Re-
place the s l i p yoke i f severely scored or rusted t o
m a i n t a i n seal a n d b u s h i n g life.
(7) A l i g n a n d i n s t a l l the propeller shaft.
(8) Check a n d top o f f the transmission l u b r i c a n t
level i f necessary. Correct level is t o the edge o f t h e
f i l l p l u g hole. Refer t o Group O, L u b r i c a t i o n and
Maintenance for lube requirements.
(9) Remove t h e d r a i n pan and lower the vehicle.
Fig. 5 Removing Yoke Seal
SPECIAL TOOL
Fig. 6 Installing Yoke Seal
GEARSHIFT LEVER
The gearshift lever is a two-piece design (Fig. 7).
The upper p a r t o f the lever is threaded to the t r a n s -
mission stub lever. The upper lever can be removed
for service w i t h o u t h a v i n g to remove the entire shift
lever assembly o r the transmission.
I f the upper lever m u s t be serviced, remove t h e
screws a t t a c h i n g the lower boot, support, bezel and
insert for access t o t h e lever lower end. T h e n u n -
thread a n d remove t h e upper lever from the stub le-
ver.
TRANSMISSION WIRING HARNESS
The transmission w i r i n g harness is attached to the
transmission and c l u t c h housing w i t h clips and t i e
straps (Fig. 8). I f the harness must be replaced, be