Chrysler Vehicle User Manual page 1149

21 - 12 MANUAL - NV1500
MANUAL - NV1500 (Continued)
Shift Socket
Inspect shift socket for wear or damage. Replace
socket if the roll pin or shift shaft bores are dam-
aged. Replace socket if the ball seat is worn, or
cracked. Do not reuse the original shift socket roll
pin. The socket roll pin is approximately is approxi-
mately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro-
ken teeth. Check condition of the bearing bore in
each gear. The bores should be smooth and free of
surface damage. Discoloration of the gear bores is a
normal occurrence and is not a reason for replace-
ment. Replace gears only when tooth damage has
occurred or if the bores are brinnelled or severely
scored.
Inspect shaft splines
Replace the shaft if the splines are damaged or bear-
ing surfaces are deeply scored, worn or brinnelled.
ASSEMBLY
SYNCHRONIZER
NOTE: The easiest method of assembling each syn-
chro is to install the springs, struts and detent balls
one at a time.
(1) Slide the sleeve part way onto the hub. Leave
enough room to install the spring in the hub and the
strut in the hub groove.
(2) Install first spring in the hub and then install
a strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide the sleeve onto the hub just far enough to
hold the first strut and spring in place.
(4) Place detent ball in the top of the strut. Then
work the sleeve over the ball to hold it in place. Use
a small flat blade screwdriver to press the ball into
place while moving the sleeve over it.
(5) Repeat procedure for the remaining springs,
struts and balls. Tape or rubber band each strut and
ball temporarily as they are installed.
(6) Verify the three springs, struts and detent balls
are all in place (Fig. 35).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears and bearings with rec-
ommended lubricant and immerse each synchro
ring in lubricant before installation. Petroleum jelly
can be used to hold parts in place.
and bearings surfaces.
Fig. 35 ASSEMBLED SYNCHRO COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
(1) Install reverse gear needle bearing on shaft
(Fig. 36). Slide bearing up against shoulder on output
shaft.
Fig. 36 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
(2) Install reverse gear over needle bearing (Fig.
37).
(3) Install solid brass synchro ring on reverse gear
(Fig. 38).
NOTE: This synchro ring is different than all the
rest. The angle on the friction face is 9° versus the
6.5° of all the other synchro rings.
TJ