NV5600 Transmission
REMOVAL1. Raise and support vehicle.
2. Remove rear propeller shaft.
3. Support transmission with suitable transmission jack.
4. Remove engine rear support.
5. Remove transfer case, if equipped.
6. Remove the bolts holding the extension/adapter housing onto the transmission gear case.
Fig. 11:
7. Using Puller 8244, remove the extension/adapter housing (Fig. 11) from the transmission gear case.
NOTE: It may be necessary to straighten the housing during removal due to the tendency for the reverse idler shaft to bind into one side of the housing.
NOTE: Be sure to retrieve the crossover cam rollers and pin from the shift rail.
Fig. 12:
8. Remove the crossover detent plug from the extension/adapter housing (Fig. 12).
9. Remove the crossover detent spring from the extension/adapter housing.
10. Remove the crossover detent plunger from the extension/adapter housing
Fig. 13:
11. Remove the bolt holding the crossover cam to the extension/adapter housing (Fig. 13).
12. Remove the crossover cam from the extension/adapter housing.
13. Remove the backup lamp switch and gasket from the extension/adapter housing.
Fig. 14:
14. Use Remover L-4518 to remove the countershaft rear bearing race from the extension/adapter housing (Fig. 14).
Fig. 15:
NOTE: Be sure to remove and tag all countershaft preload shims from between the bearing race and the housing (Fig. 15).
15. Use Remover 8240 to remove the crossover cam bushing from the extension/housing adapter.
INSTALLATION
1. Clean mating surfaces of extension/adapter housing and gear case with a wax and grease remover.
2. Check alignment dowels in gear case. Be sure dowels are in position and seated.
3. Use Installer 8239 to install the crossover cam bushing.
4. Install the countershaft preload shims into the countershaft bearing race bore.
5. Use a suitable bearing race driver to install the countershaft rear bearing race into the extension/adapter housing.
6. Install the backup lamp switch and new gasket into the extension/adapter housing.
7. Install the crossover cam into the extension/adapter housing.
8. Install the bolt to hold the crossover cam to the extension/adapter housing (Fig. 13).
9. Torque the crossover cam bolt to 47.5 Nm (35 ft. lbs.).
10. Install the crossover detent plunger into the extension/adapter housing.
11. Install the crossover detent spring into the extension/adapter housing.
12. Install the crossover detent plug into the extension/adapter housing (Fig. 12).
13. Torque the crossover cam detent plug to 47.5 Nm (35 ft. lbs.).
14. Install the crossover rollers and pin into the shift rail using sufficient petroleum jelly to hold them in place during the remainder of the installation.
15. Apply Mopar Gasket Maker to gear case and housing mating surfaces.
16. Align and install extension/adapter housing on gear case.
17. Apply Mopar Lock N' Seal, or equivalent, to threads of extension/adapter housing bolts.
18. Install and tighten housing bolts to 48 Nm (35 ft. lbs.) torque.
19. Install transfer case, if equipped.
20. Install engine rear support.
21. Install propeller shaft(s).
22. Remove transmission support stand and lower vehicle.