NV5600 Transmission
NOTE: Gaskets are not used in the NV5600 transmission. Use Mopar Gasket Maker, or equivalent, on all gear case and extension housing sealing surfaces.OUTPUT SHAFT
1. Place second gear on bench with the synchro clutch ring up.
Fig. 66:
2. Install the second gear synchro inner blocker ring onto second gear (Fig. 66).
Fig. 67:
3. Install the second gear synchro friction cone over the blocker ring and onto second gear (Fig. 67).
NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the second gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the low areas between the recesses on clutch ring.
Fig. 68:
4. Install the second gear synchro outer blocker ring over the second gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 68).
Fig. 69:
5. Install the 1-2 synchro assembly onto the second gear assembly (Fig. 69).
6. Reverse the assembly on the bench.
Fig. 70:
7. Install second gear bearing into second gear (Fig. 70).
8. Move the completed 1-2 synchro, second gear, and second gear bearing to a suitable shop press with second gear facing upward.
Fig. 71:
9. Install the output shaft into the second gear/1-2 synchro assembly with the front of the output shaft facing upward (Fig. 71).
10. Press the output shaft into position.
11. Place first gear on bench with the synchro clutch ring up.
12. Install the first gear synchro inner blocker ring onto first gear (Fig. 66).
13. Install the first gear synchro friction cone over the blocker ring and onto first gear (Fig. 67).
NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the first gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the low areas between the recesses on clutch ring.
14. Install the first gear synchro outer blocker ring over the first gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 68).
15. Reverse the output shaft in the press.
16. Install the first gear bearing sleeve onto the output shaft.
Fig. 72:
17. Install the first gear bearing sleeve the remainder of the way onto the output shaft using Installer 8228 and a shop press (Fig. 72).
Fig. 73:
18. Install the first gear and blocker assembly onto the output shaft (Fig. 73).
19. Install the first gear bearing over the output shaft and into first gear.
Fig. 74:
20. Install the output shaft thrust washer onto the output shaft (Fig. 74).
Fig. 75:
21. Install the rear output shaft bearing onto the output shaft using Installer 8228 and a shop press (Fig. 75).
22. Install a new snap-ring to hold the rear output bearing onto the output shaft. The snap-ring is selectable. Install the thickest snap-ring which will fit into the groove.
23. Reverse the output shaft in the Fixture 8227 and support the shaft with press blocks under first gear.
24. Install the sixth gear bearing onto the output shaft.
Fig. 76:
25. Install the sixth gear onto the output shaft and over the sixth gear bearing (Fig. 76).
26. Install the sixth gear friction cone onto sixth gear.
NOTE: The alignment of the high and low areas on the remaining friction cones to the matching clutch rings differs from the first two.
NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the sixth gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.
Fig. 77:
27. Install the sixth gear blocker ring over the sixth gear friction cone (Fig. 77).
Fig. 78:
28. Install Guide 8235 onto the end of the output shaft (Fig. 78).
29. Install the 5-6 synchro, over Guide 8235 and onto the output shaft.
Fig. 79:
30. Press the 5-6 synchro onto the output shaft using Installer 8156 and a shop press.
OUTPUT SHAFT POCKET BEARING
1. Install the output shaft pocket bearing onto the output shaft.
Fig. 80:
2. Press the pocket bearing the remainder of the way onto the output shaft using Guide 8235 and a shop press (Fig. 80).
3. Install a new snap-ring to hold the output shaft pocket bearing onto the output shaft.
COUNTERSHAFT
1. Place the third countershaft; gear on the bench with the synchro clutch ring up.
Fig. 81:
2. Install the third countershaft gear friction cone onto third gear (Fig. 81).
NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the third countershaft gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.
Fig. 82:
3. Install the third countershaft; gear blocker ring onto the friction cone (Fig. 82).
Fig. 83:
4. Install the 3-4 synchro assembly onto the blocker ring/gear assembly (Fig. 83).
5. Reverse the assembly on the bench.
6. Install the third countershaft; gear bearing into the third countershaft gear.
7. Install the 2-3 thrust washer onto the third gear/3-4 synchro assembly.
8. Move the third gear/3-4 synchro assembly to a suitable shop press.
9. Install the countershaft through the third gear/3-4 synchro assembly.
Fig. 84:
10. Using the shop press, press the countershaft; into the 3-4 synchro assembly (Fig. 84).
11. Install the fourth countershaft gear bearing sleeve onto the output shaft.
12. Using Installer 8228 and a suitable shop press, press the fourth countershaft bearing sleeve onto the countershaft.
13. Place the fourth countershaft gear on the bench with the synchro clutch ring up.
14. Install the fourth countershaft gear friction cone onto fourth countershaft gear (Fig. 81).
NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the fourth countershaft gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.
15. Install the fourth countershaft gear blocker ring onto the friction cone (Fig. 82).
16. Install the fourth countershaft gear bearing into the fourth countershaft gear.
17. Position the sixth countershaft gear in the shop press.
Fig. 85:
18. Position the fourth countershaft gear assembly onto the sixth countershaft gear (Fig. 85).
19. Install the countershaft into the fourth/sixth countershaft gear assembly in the shop press.
Fig. 86:
20. Using the shop press, press the countershaft into sixth gear (Fig. 86).
21. Position the fifth countershaft into the shop press.
22. Install the countershaft into the fifth countershaft gear.
Fig. 87:
23. Using the shop press, press the countershaft into fifth gear (Fig. 87).
COUNTERSHAFT BEARINGS
1. Position the front countershaft bearing onto the countershaft.
2. Using Installer 8236 and Handle C-4171, install the front countershaft bearing onto the countershaft.
3. Install a new snap-ring to hold the front countershaft bearing onto the countershaft.
4. Position the rear countershaft bearing onto the countershaft.
5. Using Installer 8236 and Handle C-4171, install the rear countershaft bearing onto the countershaft.
INPUT SHAFT
1. Position the input shaft bearing onto the input shaft.
Fig. 88:
2. Use Installer MD998805 to install the input shaft bearing (Fig. 88).
Fig. 89:
3. Position the input shaft bearing oil guide on the input shaft (Fig. 89).
4. Use Installer MD998805 to install the input shaft bearing oil guide.
5. Position the output shaft pocket bearing race in the input shaft.
Fig. 90:
6. Using Installer C-4628 and Handle C-4171, install the output shaft pocket bearing race into the input shaft (Fig. 90).
CLUTCH HOUSING
1. Using Remover/Installer 8237 and Handle C-4171, install the input shaft bearing race so that the bearing race protrudes 0.3 inch above the front surface of the clutch housing.
2. Using Remover 6061-1 and Handle C-4171, install the countershaft; front bearing race into the clutch housing so that the bearing race protrudes 0.4 inch above the front surface of the clutch housing.
Fig. 91:
3. Install the countershaft oil guide and spacer into the countershaft front bearing bore in the clutch housing (Fig. 91).
4. Clean all old sealer from the input shaft retainer and the clutch housing but DO NOT apply new sealer at this time. New sealer will be applied after all the preload measurements are made and endplay shims are installed.
5. Do not replace the input shaft seal at this time. A new seal will be installed after all the preload measurements are made and endplay shims are installed.
6. Position the input shaft retainer onto the clutch housing.
7. Install the bolts to hold the input shaft retainer onto the clutch housing.
GEARTRAIN
1. Install the input shaft into Support Stand 8246.
2. Install the fifth gear friction cone onto the input shaft.
NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the fifth gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.
3. Install the fifth gear blocker ring onto the fifth gear friction cone.
Fig. 92:
4. Install the output shaft into the input shaft (Fig. 92).
Fig. 93:
5. Install the countershaft into the Support Stand 8246 and verify that all gears are meshed with their mates on the mainshaft (Fig. 93).
6. Install Fixture 8232 to the output shaft and the countershaft.
7. Install Holding Tool 8242 onto the 5-6 synchro and tighten the screw to hold the 5-6 synchro together during the remainder of the installation procedure.
Fig. 94:
8. Attach and engine crane, or equivalent, to Fixture 8232 and move the geartrain from the Support Stand 8246 to the clutch housing (Fig. 94).
Fig. 95:
9. Install the shift forks and rails onto the geartrain (Fig. 95).
NOTE: Pay close attention to the positioning of the shift fork arms at the primary shift rail. The closest shift arm to the geartrain should be for Reverse. Next should be the arms required to give you 5-6, then 3-4, and then 1-2 when viewed moving out from the geartrain.
10. Install the geartrain and shift rails into the clutch housing. Be careful to lower the geartrain and rails into the housing slowly and avoid any binds on the shift rails, forks, and synchros as the rails enter their bushings.
Fig. 96:
11. With the geartrain approximately 1/4 inch from the clutch housing, remove Holding Tool 8242 from the 5-6 synchro (Fig. 96).
12. Install the 5-6 crossover bracket and arm to the shift rails and the clutch housing.
13. Lower the geartrain the remainder of the way into the clutch housing.
Fig. 97:
14. Install the bolts to hold the 5-6 crossover bracket to the clutch housing (Fig. 97).
15. Remove the engine crane and Fixture 8232 from the output shaft and the countershaft.
TRANSMISSION GEAR CASE
1. Using Installer C-4308 and Handle C-4171, install the rear output shaft bearing race into the transmission gear case.
2. Using Installer 8153 and Handle C-4171, install the rear countershaft bearing race into the transmission gear case.
3. Install Fixture 8232 to the transmission gear case.
NOTE: Be sure that the shift socket is loose on the shift shaft, does not have the roll-pin installed, and is rotated a minimum of 90° from its normal position in order to ensure that there is enough clearance to install the transmission gear case.
Fig. 98:
4. Attach an engine crane, or equivalent, to Fixture 8232 and install the transmission gear case onto the clutch housing (Fig. 98).
5. Install the bolts to hold the transmission gear case to the clutch housing. Torque the bolts to 48 Nm (35 ft. lbs.).
6. Using a suitable punch and hammer, install the shift socket roll pin. The correct size punch is 6 mm (7/32 inch).
MAINSHAFT AND COUNTERSHAFT ENDPLAY
1. With the transmission in vertical position, use Socket 6993 to rotate the shafts and seat the bearings.
Fig. 99:
2. Using Dial Indicator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case, measure the mainshaft endplay.
Fig. 100:
3. Using Dial Indicator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case, measure the countershaft endplay (Fig. 100).
4. Rotate the transmission into a horizontal position and remove the input shaft retainer.
5. Install the shims necessary to achieve the specified preload. The countershaft shims go between the bearing race and the spacer. The mainshaft shims go into the input shaft retainer. The correct end-play is 0.051 - 0.15 mm (0.002 - 0.006 inch) for the mainshaft and the countershaft.
6. Install a new input shaft seal into the input shaft retainer using Installer C-4965.
7. Using C-3972-A and Handle C-4171, install the input shaft oil guide.
8. Apply sealer to the input shaft retainer and install the retainer onto the clutch housing. Torque the bolts to 28 Nm (20 ft. lbs.).
9. Verify the shim selection.
REVERSE GEAR
Fig. 101:
1. Install the reverse shift fork and synchronizer as an assembly onto the reverse shift rail and the output shaft (Fig. 101). Verify that the raised square shoulder and snap-ring on the synchro face the case.
2. Using a suitable punch and hammer, install the roll-pin securing the reverse shift fork to the reverse shift rail. The correct size punch is 6 mm (7/32 inch).
Fig. 102:
3. Install the reverse gear bearing sleeve onto the output shaft (Fig. 102). It may be necessary to use Installer 6446 to install the sleeve.
Fig. 103:
4. Install reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring, and reverse gear bearing (Fig. 103).
Fig. 104:
5. Install the output shaft ball bearing assembly and reverse thrust washer onto the output shaft (Fig. 104). Note that the raised shoulder on the thrust washer faces away from the reverse gear.
6. Install a new output shaft nut onto the output shaft.
7. Using Wrench 8226 on the output shaft nut and Socket 6993, or 6984, to hold the output shaft, tighten the output shaft nut. Torque the nut to 339 Nm (250 ft. lbs.).
8. Using a suitable punch with an approximately 9 mm (5/16 inch) diameter ball end, stake the nut into the slot in the output shaft.
9. Use a suitable shop press, press the countershaft reverse gear into the sleeve.
10. Using Installer C-4652 and Handle C-4171, install the reverse countershaft rear bearing onto the countershaft reverse gear assembly.
11. Install the reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer onto the idler gear shaft.
Fig. 105:
12. Install idler and reverse countershaft gears together (Fig. 105).
13. Install the reverse idler thrust washer from the reverse idler.
Fig. 106:
14. Install the crossover cam rollers and pin (Fig. 106).
EXTENSION/ADAPTER HOUSING
1. Install the extension housing bushing with Installer 8156 and Handle C-4171, if necessary. Be sure that the oil feed hole is at the 12 o'clock position when installed.
2. On 4X2 vehicles, install the extension housing seal with Installer 8154 and Handle C-4171, with the weep hole at the bottom.
NOTE: Be sure that the drain hole located in the dust boot portion of the seal is facing downward (toward the ground) when installed.
3. On 4X4 vehicles, install the adapter housing seal with Installer C-3860-A and Handle C-4171.
4. Use Installer 8239 and Handle C-4171 to install the crossover cam bushing into the extension/adapter housing.
5. Clean the rear of the transmission case of all sealer.
6. Install the reverse countershaft gear bearing race onto the reverse countershaft gear bearing.
Fig. 107:
7. Using the Gauge Bar 6311, measure the distance from the back of the bearing race to the gauge bar (Fig. 107).
8. Measure the thickness of the gauge bar. Record the total of the two measurements.
9. Clean all the sealer from the extension/adapter housing.
Fig. 108:
10. Using Gauge Bar 6311 across the housing face, measure the distance to the bottom of the reverse countershaft bearing race bore (Fig. 108).
11. Subtract the thickness of the gauge bar from the measurement and record the result.
12. The difference between the two measurements is the endplay for the reverse countershaft gear assembly.
13. Install the required shims to achieve the correct end-play for the reverse countershaft gear assembly into the reverse countershaft bearing race bore. The correct end-play is 0.15 - 0.25 mm (0.006 - 0.010 inch).
14. Use Installer to install the reverse countershaft bearing race into the extension/adapter housing.
15. Install the back-up lamp switch and a new gasket into the extension/adapter housing. Torque the switch to 28 Nm (20 ft. lbs.).
16. Install the crossover cam into the extension/adapter housing.
Fig. 109:
17. Install the bolt to hold the crossover cam to the extension/adapter housing (Fig. 109).
18. Install the crossover detent plunger into the extension/adapter housing
19. Install the crossover detent spring into the extension/adapter housing.
Fig. 110:
20. Install the crossover detent plug into the extension/adapter housing (Fig. 110). Torque the plug to 47.5 Nm (35 ft. lbs.).
21. Apply sealer to the surface of the transmission case.
22. Install the extension/adapter housing onto the transmission case.
23. Install the bolts to hold the extension/adapter housing onto the transmission gear case. Torque the bolts to 48 Nm (35 ft. lbs.).
FINAL
1. Install the shift rail blocker bolt. Torque the bolt to 55 Nm (41 ft. lbs.).
2. Install the primary shift rail detent plunger into the transmission case.
3. Install the primary shift rail detent spring into the transmission case.
4. Install the primary shift rail detent plug into the transmission case. Torque to 47.5 Nm (35 ft. lbs.).
5. Install the shift tower onto the transmission case. Torque the bolts to 9 Nm (7 ft. lbs.).