Part 1 of 2
ASSEMBLY / NV3550 Manual Transmission Part 1CAUTION: Transmission shift components must be in the Neutral position during assembly, to prevent damage to synchros and shift components burning housing installation.
NOTE: Use Mopar Gasket Maker or equivalent, for all case joints and Mopar silicone sealer or equivalent, for the input shaft bearing retainer.
SYNCHRONIZER
NOTE: Assemble synchro springs, struts and detent balls one at a time.
1. Slide the sleeve onto the hub, leaving enough room to install the spring in the hub and strut in the hub groove.
2. Install the first spring in the hub. Then install a strut over the spring and verify the 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 the detent ball in the top of the strut. Then carefully work the sleeve over the ball to hold it in place. With a small flat blade screwdriver, press the ball into place while moving the sleeve over it.
5. Repeat the procedure for the remaining springs, struts and balls. Tape or rubber band each strut and ball to temporarily secure as they are installed.
6. Verify synchro springs, struts and detent balls are all in place (Fig. 53).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears, bearings and immerse each synchro ring with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.
1. Install reverse gear needle bearing, against the shoulder of the output shaft (Fig. 54).
2. Install reverse gear over needle bearing (Fig. 55).
3. Install brass synchro ring on reverse gear (Fig. 56).
4. Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.
NOTE: The side of the hub with the shoulder around the hub bore and tapered side of the sleeve, faces the front of the shaft.
5. Align fifth-reverse synchro assembly on output shaft splines. Seat synchro onto the shaft with Cup 6310-1 and a press (Fig. 57).
6. Install new fifth-reverse hub snap ring (Fig. 58) and verify the snap ring is seated.
NOTE: Snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to 0.086 in.). Install thickest snap ring that will fit in shaft groove.
7. Install fifth gear synchro ring in synchro hub and sleeve (Fig. 59).
8. Install fifth gear bearing by spreading bearing, just enough to clear shoulder on the output shaft (Fig. 60). Verify bearing is properly seated.
9. Install fifth gear on shaft and onto bearing (Fig. 61).
10. Invert output shaft and set shaft in Cup 6310-1 so fifth gear is seated on the tool (Fig. 62).
11. Install first gear bearing on output shaft (Fig. 62). Verify bearing is seated on shaft shoulder and is properly joined.
12. Install first gear on shaft and over bearing with bearing synchro cone facing up (Fig. 63).
13. Install first gear synchro ring (Fig. 64).
14. Assemble 1-2 synchro hub sleeve, springs, struts and detent balls.
CAUTION :One side of the synchro sleeve is marked First Gear Side. This side of the sleeve must face first gear.
15. Align 1-2 synchro assembly on the shaft (Fig. 65).
16. Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 66).
CAUTION: Ensure synchro ring and sleeve is aligned as hub is being pressed onto the shaft. The synchro ring can crack if not aligned.
17. Install interim ring.
18. Install new 1-2 synchro hub snap ring (Fig. 67) and verify the snap ring is seated.
NOTE: Snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 in.). Install thickest snap ring that will fit in shaft groove.
19. Install second gear synchro ring in 1-2 synchro hub and sleeve (Fig. 68). Verify synchro ring is properly seated.
20. Install synchro friction cone and synchro cone in synchro ring.
21. Install second gear needle bearing on shaft (Fig. 69).
22. Install second gear onto shaft and bearing (Fig. 70). Verify second gear is fully seated on synchro components.
23. Install two-piece thrust washer (Fig. 71). Ensure washer halves are seated in shaft groove and washer lugs are seated in shaft lug bores.
NOTE: Verify i.d. grooves and markings noted during removal are facing the correct direction.
24. Start retaining ring around two-piece thrust washer (Fig. 72). Ensure locating dimple is between the thrust washer halves.
25. Seat thrust washer retaining ring with plastic mallet (Fig. 73).
26. Install third sear needle bearing on shaft (Fig. 74).
27. Install third gear on shaft and bearing (Fig. 75).
28. Install third speed synchro ring on third gear (Fig. 76).
29. Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls.
30. Align 3-4 synchro hub on output shaft splines by hand (Fig. 77).
CAUTION: One side of the sleeve has grooves in it. This side of sleeve must faces the front of the shaft.
31. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 78).
NOTE: Place the pipe on hub as close to output shaft as possible without contacting the shaft splines.
32. Install new 3-4 synchro hub snap ring (Fig. 79) and verify snap ring is seated.
NOTE: Snap rings are available in thicknesses from 2.00 mm to 2.30 mm (0.078 to 0.090 in.). Install thickest snap ring that will fit in shaft groove.
33. Install output shaft bearing.
34. Install output shaft bearing snap ring, spreading it just enough to install it (Fig. 80). Verify snap ring is seated in shaft groove.
35. Verify position of synchro sleeves before proceeding with assembly operations (Fig. 81). Grooved side of 3-4 sleeve should be facing forward. First gear side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.
REVERSE IDLER ASSEMBLY
1. Lubricate idler components with gear lube.
2. Slide idler gear bearing on shaft (Fig. 82). Bearing fits either way on shaft.
3. Slide gear onto shaft with recess to the rear (Fig. 82).
4. Place first lock ball in dimple at rear end of idler shaft (Fig. 82). Hold ball in place with petroleum jelly.
5. Slide thrust rear thrust washer onto shaft and over lock ball (Fig. 83).
6. Install snap ring in groove at rear of shaft (Fig. 83).
7. Install lock ball in dimple at front of shaft. Hold ball in place with petroleum jelly.
8. Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 84).
9. Install wave washer, flat washer and remaining snap ring on idler shaft (Fig. 84). Verify snap ring is seated.
SHIFT SHAFT AND BUSHINGS/BEARINGS
1. Locate a bolt that will thread into the bushing without great effort.
2. Thread the bolt into the bushing, allowing the bolt to make its own threads in the bushing.
3. Attach a slide hammer or suitable puller to the bolt and remove bushing.
4. Use the short end of Installer 8119 to install the new bushing.
5. The bushing is correctly installed if the bushing is flush with the transmission case.
6. To replace the bearing locate a bolt that will thread into the bearing without great effort.
7. Thread the bolt into the bearing as much as possible.
8. Attach a slide hammer or suitable puller to the bolt and remove the bearing.
9. Use the short end of Installer 8119 to install the new bearing.
10. The bearing is correctly installed if the bearing is flush with the transmission case.
DETENT PLUNGER BUSHING
NOTE: The detent plunger bushings are installed to a specific depth. The space between the two bushings, when correctly installed, contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted.
1. Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore.
2. Remove the bushings from the shift shaft bore.
3. Install a new detent plunger bushing on the long end of Installer 8118.
4. Start the bushing in the detent plunger bore in the case.
5. Drive the bushing into the bore until the tool contacts the transmission case.
6. Install a new detent plunger bushing on the short end of Installer 8118.
7. Start the bushing in the detent plunger bore in the case.
8. Drive the bushing into the bore until the tool contacts the transmission case.