Chrysler Vehicle User Manual page 1169

21 - 32 MANUAL - NV3550
MANUAL - NV3550 (Continued)
Leaks can occur at the mating surfaces of the gear
case and adaptor or from the front/rear seals. A sus-
pected leak could also be the result of an overfill con-
dition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non–recommended sealer.
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 conse-
quence of using non–recommended lubricants is noise,
excessive wear, internal bind, and hard shifting. Sub-
stantial lubricant leaks can result in gear, shift rail,
synchro, and bearing damage. If a leak goes undetec-
ted for an extended period, the first indications of com-
ponent damage are usually hard shifting 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.
Incorrect adjustment or a worn/damaged pressure
plate or disc can cause incorrect release. If the 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. Insuf-
ficient, 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.
REMOVAL
(1) Shift transmission into first or third gear.
(2) Remove the floor console and shift boot as nec-
essary to access the bottom of the shift lever at the
shift tower attachment.
(3) Remove shift tower bolts and remove shift
tower and shift lever assembly.
(4) Raise and support vehicle on suitable safety
stands.
(5) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.
(6) Remove skid plate, if equipped.
(7) Remove crossmember.
(8) Disconnect necessary exhaust system compo-
nents.
(9) Remove slave cylinder (Fig. 2) from clutch
housing.
Fig. 2 Slave Cylinder
1 - CLUTCH SLAVE CYLINDER
(10) Mark rear propeller shaft and rear axle yokes
for installation alignment (Fig. 3).
(11) Mark front propeller shaft, axle and transfer
case yokes for installation alignment.
(12) Remove propeller shafts.
(13) Unclip wire harnesses from transmission and
transfer case.
(14) Disconnect transfer case shift linkage at
transfer case.
(15) Remove nuts attaching transfer case to trans-
mission.
(16) Remove transfer case.
TJ