Assembly
ASSEMBLY / NV1500 Manual TransmissionSYNCHRONIZER
NOTE: The easiest method of assembling each synchro 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. 34).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears and bearings with recommended lubricant and immerse each synchro ring in lubricant before installation. Petroleum jelly can be used to hold parts in place.
1. Install reverse gear needle bearing on shaft (Fig. 35). Slide bearing up against shoulder on output shaft.
2. Install reverse gear over needle bearing (Fig. 36).
3. Install solid brass synchro ring on reverse gear (Fig. 37).
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.
4. Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Cup 6310-1 (Fig. 38).
CAUTION: Fifth-reverse synchro hub and sleeve can be installed backwards. One side of the sleeve has double grooves and offset teeth. This side must be installed away from reverse gear (towards 5th).
NOTE: The synchro hub is a press fit design. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.
5. Install new fifth-reverse hub snap ring (Fig. 39) and verify snap ring is seated in the shaft groove.
NOTE: Install thickest snap ring that will fit in shaft groove.
6. Install fifth gear synchro ring in synchro hub and sleeve (Fig. 40).
7. Install fifth gear bearing, spreading bearing only enough to clear shoulder on output shaft (Fig. 41). Verify bearing is seated.
8. Install fifth gear on shaft and onto bearing (Fig. 42).
9. Install output shaft bearing.
10. Install output shaft bearing snap ring, spread snap ring only enough to install it (Fig. 43). Verify snap ring is seated in shaft groove.
11. Invert output shaft and set the shaft in Cup 6310-1 so that fifth gear is seated on the tool (Fig. 44).
12. Install first gear bearing on output shaft (Fig. 44). Verify bearing is seated on shaft shoulder and is properly joined.
13. Install synchro cone onto first gear. Verify synchro cone locating tabs are properly located to the recesses in first gear.
14. Install first gear on shaft and over bearing with bearing synchro cone facing up (Fig. 45).
15. Install first gear synchro ring (Fig. 46).
16. Start 1-2 synchro assembly on shaft by hand (Fig. 47). Be sure synchro sleeve is properly positioned.
CAUTION: The 1-2 synchro hub and sleeve can be installed backwards. One side of the sleeve has a groove and offset teeth. This side must be installed towards 1st gear (away from 2nd gear).
NOTE: The synchro hub is a press fit design. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.
17. Press 1-2 synchro onto output shaft with suitable size pipe and shop press (Fig. 48).
CAUTION: Align synchro ring and sleeve as hub is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.
18. Install new 1-2 synchro hub snap ring (Fig. 49) with the thickest snap ring that will fit in shaft groove. Verify snap ring is seated in shaft groove.
19. Install second gear synchro ring in 1-2 synchro hub and sleeve (Fig. 50). Verify synchro ring is seated in sleeve.
20. Install synchro cone into synchro ring.
21. Install second gear needle bearing on shaft (Fig. 51).
22. Install second gear onto shaft and bearing (Fig. 52). Verify second gear is seated on synchro components.
23. Install thrust washer pin to shaft and install two-piece thrust washer (Fig. 53). Verify washer halves are seated in shaft groove and pin reliefs are positioned at washer locating pin.
24. Seat retaining ring around two-piece thrust washer.
25. Install third gear needle bearing on shaft (Fig. 54).
26. Install third gear on shaft and bearing (Fig. 55).
27. Install third speed synchro ring on third gear (Fig. 56).
28. Start 3-4 synchro hub on output shaft splines by hand (Fig. 57).
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards. One side of the sleeve has two grooves and offset teeth. This side must be installed towards 3rd gear (away from 4th gear).
NOTE: The synchro hub is a press fit design. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.
29. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 58). Press tool must be as close to the hub center as possible but not contacting the shaft splines.
30. Install 3-4 synchro hub new snap ring (Fig. 59) with thickest snap ring that will fit in shaft groove. Verify snap ring is seated in groove.
31. Verify position of synchro sleeves before proceeding (Fig. 60).
GEARTRAIN
1. Install input shaft into Support Stand 8355 (Fig. 61).
2. Install pilot bearing in input shaft (Fig. 61).
3. Install fourth gear synchro ring on input shaft (Fig. 62).
4. Install assembled output shaft and geartrain in input shaft (Fig. 63). Rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
5. Slide countershaft into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears (Fig. 64).
6. Thread one Pilot Stud 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear.
7. Assemble 1-2 and fifth reverse-shift forks (Fig. 65). Arm of fifth-reverse fork goes through slot in 1-2 fork.
8. Install assembled shift forks in synchro sleeves (Fig. 66). Verify forks are seated in sleeves.
REAR HOUSING
1. Lubricate countershaft rear bearing race.
2. Install rear housing onto geartrain (Fig. 67). Verify bearing retainer pilot stud is in correct bolt hole and countershaft and output shaft bearings are aligned in housing and on countershaft.
3. Seat rear housing on output shaft rear bearing and countershaft. Tap housing into place with plastic or rawhide hammer.
4. Apply Mopar Gasket Maker or equivalent to bolt threads, bolt shanks and under bolt heads (Fig. 68).
5. Start first two bolts in retainer (Fig. 69). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts.
6. Remove Pilot Stud 8120 and install last retainer bolt (Fig. 69).
7. Tighten all three retainer bolts to 22 Nm (16 ft. lbs.).
NOTE: All bolts except the reverse idler shaft bolts have O-rings to seal the bolts to the transmission case. Inspect the O-rings to ensure that they are in good condition.
REVERSE IDLER
1. Remove geartrain and housing assembly from support stand with aid of helper.
2. Assemble shaft, gear and washer (without bearing or support) and install into housing (Fig. 70).
NOTE: The small shoulder on the reverse idler gear goes toward the front of the transmission.
3. Apply Mopar Gasket Maker or equivalent sealer to underside of idler shaft and support bolt heads, bolt shanks and bolt threads (Fig. 68).
4. Align hole in housing with threaded hole in shaft and start shaft rear bolt a few threads.
5. Install bearing into position.
6. Install segment (Fig. 70), align housing hole with segment threaded hole, and start support bolt a few threads.
7. Tighten large idler shaft bolt to 43 Nm (31.7 ft. lbs.). Tighten small idler shaft bolt to 22 Nm (16.2 ft. lbs.).
CAUTION: Verify idler shaft and support segment are properly seated and firmly in place while tightening the shaft bolts. The segment, housing or shaft threads can be damaged if the idler shaft is allowed to shift out of position.
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET
1. Verify all synchro sleeves are in Neutral position (centered on hub).
CAUTION: Synchros must all be in Neutral position to prevent damage to the housings, shift forks and gears during installation of the two housings.
2. Install 3-4 shift fork in synchro sleeve (Fig. 71). Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms.
3. Slide shift shaft through the shift forks (Fig. 72).
4. Assemble shift shaft shift lever and bushing (Fig. 73). Slot in bushing must face up and roll pin hole for lever to align with hole in shaft.
5. Install assembled lever and bushing on shift shaft (Fig. 74).
6. Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (Fig. 75).
7. Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 76).
8. Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing.
CAUTION: Positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 180° off. If this occurs, transmission will have to be disassembled to correct shaft alignment.
9. Select correct new roll pin for shift shaft lever (Fig. 77). Shaft lever roll pin is approximately 22 mm (7/8 inch) long. Shift socket roll pin is approximately 33 mm (1-1/4 inch) long.
10. Align roll pin holes in shift shaft, lever and bushing, then start roll pin into shaft lever by hand (Fig. 78).
11. Seat shaft lever roll pin with pin punch (Fig. 79).
CAUTION: Shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.
12. Verify lock pin slot in lever bushing is positioned as shown (Fig. 79).
13. Align roll pin holes in shift socket and shift shaft. Then start roll pin into shift shaft by hand (Fig. 80).
14. Seat roll pin in shift socket with pin punch. Roll pin must be instated flush with socket (Fig. 81). 15. Verify notches in shift fork arms are aligned.
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
1. If previously removed, install input shaft bearing in front housing bore (Fig. 82). Install snap ring and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.
2. Apply small amount of petroleum jelly to shift shaft bushing in front housing (Fig. 83).
3. Apply 1/8 inch wide bead of Mopar Gasket Maker or equivalent to mating surfaces of front and rear housings (Fig. 83).
4. Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain.
5. Work front housing downward onto geartrain until seated on rear housing.
CAUTION: If the front housing will not seat on the rear housing, the shift components are not in Neutral, or one or more components are misaligned. Do not force the front housing into place.
6. Place transmission in horizontal position.
7. Apply Mopar Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 84).
8. Install and start housing attaching bolts by hand (Fig. 84). Then tighten bolts to 34 Nm (25 ft. lbs.).
9. Install shift shaft bushing lock bolt (Fig. 85). Apply Mopar Gasket Maker or equivalent to bolt threads, shank and underside of bolt head before installation.
CAUTION: If the lock bolt cannot be fully installed, do not try to force it into place. Either the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned.
10. Remove countershaft bearing shim cap and shim. Attach a dial indicator and move countershaft front and back to measure shaft end play. The required countershaft pre-load 0.001-0.003 inches. Add this amount to the measured amount of countershaft end-play. This gives the amount of shims necessary to correctly pre-load the front and rear countershaft bearings.
11. Install the selected shims and the shim cap. Tighten shim cap bolts to 29 Nm (21.4 ft. lbs.). Verify the shim selection by rotating the input shaft by hand with the transmission in neutral. The proper torque required to rotate the input shaft and the countershaft, is approximately 5-7 inch lbs. The input shaft should therefore be easily rotated by hand. If the input shaft cannot be rotated by hand or is not smooth through several rotations, re-check the countershaft pre-load.
12. Lubricate then install shift shaft detent plunger in housing bore. Verify plunger is fully seated in detent notch in shift shaft.
NOTE: Lubricate plunger with Valvoline Dura blends Semi-Synthetic or Synthetic grease or equivalent.
13. Install detent plug in end of Installer 8123. Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore. Drive detent plug into transmission case until plug seats.
14. Install backup light switch (Fig. 86).
15. Install input shaft snap ring (Fig. 87).
16. Install new oil seal in front bearing retainer with Installer 6448 (Fig. 88).
17. Apply bead of Mopar Silicone Sealer or equivalent to flange surface of front bearing retainer.
18. Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 89). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.
NOTE: Be sure that no sealer gets into the oil feed hole in the transmission case or bearing retainer.
19. Install and tighten bearing retainer bolts to 29 Nm (21.4 ft. lbs.) (Fig. 90).
SHIFT TOWER AND LEVER
1. Apply petroleum jelly to ball end of shift lever and interior of shift socket.
2. Shift the transmission into third gear.
3. Align and install shift tower and lever assembly (Fig. 91). Verify shift ball is seated in socket and offset in the tower is toward the passenger side of the vehicle before installing tower bolts.
4. Install shift tower bolts (Fig. 92), and tighten bolts to 8.5 Nm (75.2 inch lbs.).
5. Fill transmission to bottom edge of fill plug hole with Mopar Transmission.
6. Install and tighten fill plug to 34 Nm (25 ft. lbs.).
7. Check transmission vent. Be sure vent is open and not restricted.