Dodge ZB 2005 Service Manual page 855

21 - 4 MANUAL TRANSMISSION - T56
MANUAL TRANSMISSION - T56 (Continued)
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab, and/or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants is
noise, excessive wear, internal bind, and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Shift component damage, incorrect clutch adjust-
ment or a damaged clutch pressure plate or disc are
additional probable causes of increased shift effort. If
clutch problem is advanced, gear clash during shifts
can result. Worn or damaged synchro rings can cause
gear clash when shifting into any forward gear. In
some new or rebuilt transmissions, new synchro
rings may tend to stick slightly causing hard or noisy
shifts. In most cases, this condition will decline as
the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe, highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear and bearing
damage.
STANDARD PROCEDURE - DRAIN AND FILL
CAUTION: Hypoid gear lube must not be used in
this transmission. Use of hypoid gear lube will
cause hard shifting effort/transmission failure.
(1) Raise and support vehicle.
(2) Remove belly pan.
(3) Remove drain plug located on the right side of
the transmission tail housing.
(4) Remove transmission fill plug located on the
left side of the transmission case.
(5) Install drain plug into tail housing.
(6) Fill transmission with Mopar Synthetic Man-
ual Trans Lubricant 75W-85. The transmission is full
when the fluid level is even with the bottom of the
fill hole.
(7) Install transmission fill plug.
(8) Install belly pan.
REMOVAL
(1) Disconnect battery power source.
(2) Lift vehicle on hoist.
(3) Remove belly pan and front extension.
(4) Remove drive shaft.
(5) Disconnect hydraulic clutch quick connector at
the transmission bell housing. Use Clutch Line Dis-
connect Tool 6638 or 6638A to disconnect.
(6) Install a screw-type support stand underneath
engine oil pan.
(7) Raise the engine/transmission slightly with
support stand. Remove the transmission crossmem-
ber (Fig. 4) and mount bolts/nuts.
Fig. 4 TRANSMISSION CROSSMEMBER
1 - TRANSMISSION MOUNT
2 - CROSSMEMBER
(8) Slightly lower engine/transmission with sup-
port stand. Do not allow the engine/transmission
assembly to hang freely.
(9) Using a crow-foot wrench, unscrew the isolator/
shifter handle from the shifter tower.
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