Dodge D150 1990 Service Manual page 885

21 - 34 MANUAL TRANSMISSION •
Fig. 72 Replacing Extension Housing Bushing
synchronizer components a n d a l l bearings and bear-
i n g contact surfaces b e f o r e assembly a n d i n s t a l l a -
t i o n .
Assemble t h e transmission o n a clean w o r k sur-
face. D o n o t allow d i r t or foreign m a t e r i a l t o enter
the case or gear components d u r i n g assembly opera-
tions.
V e r i f y t h a t bearings cups a n d cones are correctly
positioned before s t a r t i n g assembly operations.
ASSEMBLING GEAR SET
(1) Assemble 1-2 and 3-4 synchronizers (Fig. 44).
(2) I n s t a l l center b e a r i n g snap r i n g , caged needle
bearings a n d first gear o n mainshaft ( F i g . 43). B e
s u r e t h e c h a m f e r e d s i d e o f t h e s n a p r i n g f a c e s
t h e first g e a r .
(3) I n s t a l l 1-2 synchronizer assembly (Fig. 42) a n d
i n s t a l l assembly r e t a i n i n g snap r i n g (Fig. 41).
(4) I n s t a l l second gear (Fig. 40).
(5) I n s t a l l two-piece t h r u s t washer, r e t a i n i n g r i n g
and a n t i - s p i n pins ( F i g . 38). Note washer and r i n g
position before i n s t a l l a t i o n (Fig. 39).
(6) I n s t a l l t h i r d speed gear (Fig. 37) and 3-4 syn-
chronizer assembly (Fig. 36).
(7) I n s t a l l snap r i n g gear set snap r i n g (Fig. 35).
CENTER SUPPORT PLATE/REVERSE IDLER
ASSEMBLY
(1) I n s t a l l countershaft gear center bearing snap
r i n g (Fig. 52).
(2) I n s t a l l new O-rings o n reverse i d l e r shaft. T h e n
lubricate, assemble a n d i n s t a l l i d l e r gear, shaft,
bearings and spacer i n support (Fig. 51).
(3) I n s t a l l idler shaft snap r i n g (Fig. 50).
ADJUSTING COUNTERSHAFT GEAR END
PLAY
(1) I n s t a l l countershaft gear i n support plate ( F i g .
73).
(2) I n s t a l l support plate and gear i n case.
(3) I n s t a l l and t i g h t e n support-to-gear case bolts
snug b u t not to final torque.
(4) I n s t a l l o r i g i n a l countershaft gear end play s h i m
and attach extension t o support and case.
(5) A t t a c h d i a l indicator t o f r o n t o f case and posi-
t i o n indicator plunger against countershaft gear (Fig.
(6) Move gear forward and zero indicator.
(7) Move gear r e a r w a r d a n d note d i a l indicator
reading. E n d play should be . 0 3 t o .13 m m ( . 0 0 1 t o
. 0 0 5 inch).
(8) I f necessary, select new s h i m (Fig. 74).
(9) Remove d i a l indicator a n d countershaft gear
and continue w i t h assembly.
Fig. 73 Measuring Countershaft Gear End Play
Port No.
Thickness
Port No.
Millimeters Inches
4338275
1.37-1.39 .0539
4338276 1.46-1.48 .0579
4338277 1.55-1.57 .0614
4338278 1.64-1.66 .0650
4338279 1.73-1.75 .0685
4338280 1.82-1.84 .0720
4338281 1.91-1.93 .0756
4338282 2.00-2.02 .0791
4338283 2.09-2.11 .0827
4338284 2.18-2.20 .0862
4338285 2.27-2.29 .0898
J9021-100
Fig. 74 Countershaft Gear End Play Shim Chart
INPUT SHAFT INSTALLATION
(1) Coat mainshaft p i l o t r o l l e r bearings w i t h petro-
l e u m j e l l y and i n s t a l l rollers i n shaft (Fig. 49). E x t r a
petroleum j e l l y can be used t o hold rollers i n place.
(2) Insert i n p u t shaft i n t o f r o n t bearing bore f r o m
inside case (Fig. 48).
(3) Seat shaft i n bore and i n s t a l l locating snap r i n g
on f r o n t bearing (Fig. 47).
(4) I n s t a l l new retainer gasket on case a n d i n s t a l l
front bearing retainer ( F i g . 46). T i g h t e n r e t a i n e r
bolts t o 28 N-m (21 ft-lbs) torque.
GEAR SET AND SUPPORT PLATE ASSEMBLY
(1) I n s t a l l countershaft gear i n support plate ( F i g .
34).