manual - nv3550

MANUAL - NV3550TABLE OF CONTENTS� � � � � � � �� ! � " � � � � � � � � � � � � � � � � � � � � � � � � � � �� # � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � # � � � � � ! � " � � � � � � � � � � � � � � � � � � � � � � � � � � � � # $

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up-shifting or down-shifting). The synchronizer doesthis by having the synchronizer hub splined to themainshaft and moving the blocker ring into contactwith the gear’s friction cone. As the blocker ring andfriction cone come together, the gear speed is broughtup or down to the speed of the synchronizer. As thetwo speeds match, the splines on the inside of thesynchronizer sleeve become aligned with the teeth onthe blocker ring and the friction cone and eventuallywill slide over the teeth, locking the gear to themainshaft through the synchronizer.DIAGNOSIS AND TESTINGLOW LUBRICANT LEVELA low transmission lubricant level is generally theresult of a leak, inadequate lubricant fill, or an incor-rect lubricant level check.

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TJ MANUAL - NV3550 21 - 31

Leaks can occur at the mating surfaces of the gearcase 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 ofinadequate sealer, gaps in the sealer, incorrect bolttightening, or use of a non–recommended sealer.A leak at the front of the transmission will be fromeither the front bearing retainer or retainer seal.Lubricant may be seen dripping from the clutchhousing after extended operation. If the leak issevere, 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 madewhen the vehicle is level. Also allow the lubricant tosettle for a minute or so before checking. These rec-ommendations will ensure an accurate check andavoid an underfill or overfill condition. Always checkthe lubricant level after any addition of fluid to avoidan incorrect lubricant level condition.HARD SHIFTINGHard shifting is usually caused by a low lubricantlevel, 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 areadditional probable causes of increased shift effort.Incorrect adjustment or a worn/damaged pressureplate or disc can cause incorrect release. If the clutchproblem is advanced, gear clash during shifts canresult. Worn or damaged synchro rings can causegear clash when shifting into any forward gear. Insome new or rebuilt transmissions, new synchrorings may tend to stick slightly causing hard or noisyshifts. In most cases, this condition will decline asthe rings wear-in.TRANSMISSION NOISEMost manual transmissions make some noise dur-ing normal operation. Rotating gears generate a mildwhine that is audible, but generally only at extremespeeds.Severe, highly audible transmission noise is gener-ally the initial indicator of a lubricant problem. Insuf-ficient, improper, or contaminated lubricant willpromote rapid wear of gears, synchros, shift rails, forksand bearings. The overheating caused by a lubricantproblem, 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 theshift tower attachment.(3) Remove shift tower bolts and remove shifttower and shift lever assembly.(4) Raise and support vehicle on suitable safetystands.(5) Support engine with adjustable jack stand.Position wood block between jack and oil pan toavoid 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 clutchhousing.

(10) Mark rear propeller shaft and rear axle yokesfor installation alignment (Fig. 3).(11) Mark front propeller shaft, axle and transfercase yokes for installation alignment.(12) Remove propeller shafts.(13) Unclip wire harnesses from transmission andtransfer case.(14) Disconnect transfer case shift linkage attransfer case.(15) Remove nuts attaching transfer case to trans-mission.(16) Remove transfer case.

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21 - 32 MANUAL - NV3550 TJMANUAL - NV3550 (Continued)

(17) Remove crankshaft position sensor (Fig. 4).

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(24) Pull transmission jack rearward until inputshaft clears clutch. Then slide transmission out fromunder vehicle.(25) Remove clutch release bearing, release forkand retainer clip.(26) Remove clutch housing from transmission.DISASSEMBLYFRONT HOUSING(1) Shift transmission into Neutral.(2) Remove drain plug and drain lubricant.(3) Inspect drain plug magnet for debris.(4) Remove backup light switch. Switch is locatedon passenger side of rear housing (Fig. 5).

(5) Remove shift tower bolts and remove tower andlever assembly (Fig. 6).

(6) Remove shift shaft lock bolt (Fig. 7) located ontop of the housing just forward of shift tower.

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TJ MANUAL - NV3550 21 - 33MANUAL - NV3550 (Continued)

(7) Remove shift shaft detent plug with Remover8117A. Attach the fingers of the remover to thedetent plug (Fig. 8). Then push the cup down till itcontacts the trans. Tighten the nut (Fig. 9) till itpulls the plug from the trans case.

(8) Remove shift shaft detent plunger and spring.Remove spring and plunger with a pencil magnet.(9) Remove bolts attaching input shaft bearingretainer to front housing and remove retainer.Ü Ý Þ ß à á â ã ä å æ ç è è é ç è ê ë å ã ì í é é æ é î ì ç å ã ç ë î ï ã å ë ï ðñ å ã ë ò â ã ë é ã å ñ ã ë ð ó ô î õ ö ÷ ø ù ö(10) Remove bearing retainer from input shaft(Fig. 11).

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(11) Remove snap ring that secures input shaft infront bearing (Fig. 12).

(12) Remove bolts that attach front housing to rearhousing.(13) Separate front housing from rear housing(Fig. 13). With a plastic mallet tap the front housingoff the alignment dowels.

(14) Remove and inspect input shaft bearing andcountershaft front bearing (Fig. 14).

(15) Remove screw from reverse blocker andremove blocker (Fig. 15) from case.- . / 0 1 / 2 3 4 3 5 3 4 6 3 7 8 9 : ; 3 4 < 6 9 = 8 > ? 6 3 @ 9 = A B C5 3 2 < : 8 3 6 DE F G H I J K L M N O P Q R E O P L R M S K L TU V W X Y Z [ \ ] ^ _ [ \ X ^ Y ` W X ab V c W d _ e e f

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(16) Note the location of the input shaft, shiftshaft, shift forks and geartrain (Fig. 16).

SHIFT/FORK SHAFTS AND REVERSE IDLERSEGMENT(1) Unseat the roll pin that secures the shiftsocket to the shift shaft with Remover 6858 as fol-lows:(a) Position remover on the shift shaft. Centerthe tool over the roll pin and verify that the toollegs are firmly seated on the shift socket (Fig. 17).(b) Tilt the socket toward the side of the case.This positions the roll pin at a slight angle to avoidtrapping the pin between the gear teeth.(c) Tighten the tool to press the roll pin down-ward and out of the shift socket (Fig. 17).~ � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �� (2) Rotate lever and bushing upward and out ofthe shift forks and catch detent ball and spring (Fig.18) as they exit the shaft lever.

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(3) With a hammer and punch drive out roll pinthat secures shift bushing and lever to shift shaft(Fig. 19).� � � � � � ~ � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � ��

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(4) Pull shift shaft straight (Fig. 20) out of rearhousing.

(5) Remove shift socket from rear housing (Fig.21).(6) Remove lever and bushing (Fig. 22).(7) Rotate 3-4 fork around synchro sleeve untilfork clears shift arms on 1-2 and fifth-reverse forks,then remove 3-4 fork (Fig. 23).

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(8) Remove the reverse idler shaft support bolt(front bolt) (Fig. 24).(9) Loosen rear reverse idler shaft bolt (rear bolt)(Fig. 24).

(10) Remove reverse idler shaft support (Fig. 25)segment by sliding it straight out of housing.

(11) Support geartrain and rear housing on Fix-ture 6747 as follows:(a) Adjust height of reverse idler pedestal roduntil the reverse idle shaft bottoms in Cup 8115.(b) Position Adapters 6747-1A and 6747-2A onFixture 6747.(c) Slide fixture tool onto input shaft, counter-shaft and idler gear (Fig. 26).

(d) Stand geartrain and rear housing upright onfixture (Fig. 27). Have helper hold fixture tool inplace while housing and geartrain is being rotatedinto upright position.

(12) Remove rear bolt holding reverse idler shaftin housing.

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REAR ADAPTER HOUSING(1) Locate rear seal dimples (Fig. 28). With slidehammer mounted screw, remove rear seal by insert-ing screw into one of the seal dimples (Fig. 29).

(2) Remove rear bearing snap ring from outputshaft with snap ring pliers (Fig. 30).(3) Lift rear adapter housing upward and offgeartrain (Fig. 31).(4) Remove bearing retainer bolts and remove rearbearing retainer and rear bearing (Fig. 32). If neededpush or tap bearing out of the housing with a ham-mer.

(5) Examine condition of bearing bore, counter-shaft rear bearing race and idler shaft notch in rearhousing. Replace housing if race, bore or notch areworn or damaged.GEARTRAIN FROM FIXTURE(1) Remove reverse idler gear assembly fromassembly fixture cup.(2) Remove 1-2 and fifth-reverse forks from syn-chro sleeves.(3) Slide countershaft out of fixture tool.(4) Lift and remove output shaft and gears offinput shaft.(5) Lift and remove input shaft, pilot bearing andfourth gear synchro ring from assembly fixture tool.

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OUTPUT SHAFTv w x y z x { | } ~ � � { � � � � � | � { � � } � � � } � | | � | } � � | � � � �� | � | � � � � � � � } � � � � � | � � � | � � � � | � � � | � � � | | � � {} ~ � � { � � � � � | � � � � � � } � � � } } | � � � ~ � � � � � � � � � � | � � � � �� } � � | � | � | � � | � � � � � � � � � | � � { } ~ � � { � � { � �� } � | | � | � � � � � � � | � � � } } | � � � ~ �(1) Remove snap ring that secures 3-4 synchro hubon output shaft.(2) Remove 3-4 synchro assembly, third gear synchroring and third gear with shop press and Bearing Splitter1130. Position splitter between second and third gears.(3) Remove third gear needle bearing (Fig. 33).

(4) Remove retaining ring that secures two-piecethrust washer on shaft (Fig. 34). Use a small pry toolto remove retaining ring.

(5) Remove two-piece thrust washer (Fig. 35). Noteposition of washer locating lugs in shaft notches forinstallation reference.

(6) Remove second gear and needle bearing (Fig.36).(7) Remove second gear synchro ring, synchro fric-tion cone and synchro cone (Fig. 37).(8) Remove interim ring.(9) Remove 1-2 synchro hub snap ring.(10) Remove 1-2 synchro hub and sleeve and firstgear from output shaft with press and Bearing Split-ter 1130 (Fig. 38). Position splitter between first andreverse gears.

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(11) Remove first gear needle bearing (Fig. 39).

(12) Remove fifth gear (Fig. 40).

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(14) Remove fifth-reverse synchro hub snap ring(Fig. 42).

(15) Remove fifth-reverse synchro hub and sleevewith a press (Fig. 43).

(16) Remove reverse gear and needle bearing (Fig.44).

REVERSE IDLER(1) Remove idler gear snap rings (Fig. 45).(2) Remove thrust washer, wave washer, thrustplate and idler gear from shaft.(3) Remove idler gear needle bearing from shaft.CLEANINGClean the gears, shafts, shift components andtransmission housings with a standard parts clean-ing solvent. Do not use acid or corrosive base sol-vents. Dry all parts except bearings with compressedair.Clean the shaft bearings with a mild solvent suchas Mopart degreasing solvent, Gunk, or similar sol-vents. Do not dry the bearings with compressed air.Allow the bearings to either air dry, or wipe them drywith clean shop towels.INSPECTION" # $ % & ' ( ) * + ) ( , - . * ) , * / 0 * ) 1 ) 2 . 3 + 4 5 , 1 . , 5 ) 6 1. / * * 2 7 1 8 9 ( 2 7 : ; < = > ; < ? + ( 2 1 / 1 + @ . * 5 - 1 8 ( ) * ( A 5 ) 84 ( ) 5 A 0 * A ( . 7 1 8 9 ( 2 7 , + * , 3 . , A * 2 7 BSHIFT LEVER ASSEMBLYThe shift lever assembly is not serviceable. Replacethe lever and shift tower as an assembly if the tower,lever, lever ball, or internal components are worn, ordamaged.

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SHIFT SHAFT AND FORKSInspect the shift fork interlock arms and synchrosleeve contact surfaces (Fig. 46). Replace any forkexhibiting wear or damage in these areas. Do notattempt to salvage shift forks.Check condition of the shift shaft detent plungerand spring. The plunger should be smooth and free ofnicks, or scores. The plunger spring should bestraight and not collapsed, or distorted. Replace theplunger and spring if in doubt about condition. Checkcondition of detent plunger bushings. Replace if dam-aged.Inspect the shift shaft, shift shaft bushing andbearing, the shaft lever, and the lever bushing thatfits over the lever. Replace the shaft if bent, cracked,or severely scored. Replace the shift shaft bushing orbearing if damaged.Replace the shaft lever and bushing if either partis deformed, or worn. Do not attempt to salvage theseparts as shift fork binding will occur. Replace the rollpin that secures the lever to the shaft.FRONT/REAR HOUSINGS AND BEARINGRETAINERSInspect the housings carefully. Look for cracks,stripped threads, scored mating surfaces, damagedbearing bores, or worn dowel pin holes. Minor nickson mating surfaces can be dressed off with a fine file,or emery cloth.u v w x y w z { | } ~ � � z ~ � � � � � � ~ � � � � � � � z { � ~ � � � { } � z � | �| } ~ � � � { � } � � � } � � { � w z { } { � } z ~ � � � � � � ~ � � � � � � � z {� ~ � � � { } � z � | � } { � } � { � } � � � } � � { � � { � � � � � { � � z � �� z { � { � ~ � � ~ � { � � � � } { u v w � { } � � � { � � � { � � { � � � w z {| } ~ � � z ~ � � � � � � � � � z � � { � ~ � { } { � � � � { � � | � z { � ~ � � �

� { } � z � | � � { � } � � � } � � { � � � ~ ~ � { � � ~ } � � ~ } � � � � � { � �w z { } { � } z ~ � � � � � � � � � z � � { � ~ � { } { � � � � { � � | � z {� ~ � � � { } � z � | � } { � } � { � } � � � } � � { � � � ~ ~ � { � � ~ } � � ~ }� � � � � { � �Inspect the input shaft bearing retainer. Be surethe release bearing slide surface of the retainer is ingood condition. Replace the retainer seal if necessary.Inspect the output shaft bearing retainer. Be surethe U-shaped retainer is flat and free of distortion.Replace the retainer if the threads are damaged, or ifthe retainer is bent, or cracked.

COUNTERSHAFT BEARINGS AND RACESThe countershaft bearings and races are machinelapped during manufacture to form matched sets.The bearings and races should not be interchanged.u v w x y w z { � { � } � � � } � � { � � } { � � { } � � � { � � � } { � � | � �� z { z ~ � � � � � � � � � � } { u v w � { } � � � { � � � { � � | � � { � } �� } � � { � { � ~ � { � � � � � � { � � � � � � � � � { � { � { � � � } � � ~} { � � � � { � z { | } ~ � � ~ } } { � } z ~ � � � � � � � � { � { � � � } � � �� { � � ~ � � � { } � z � | � � { � } � � � � � � � � { � � � � � � { � � � � z { � � z� { � z ~ � � � � � | ~ } � { } � � � { � � { �The countershaft bearings can be installed back-wards if care is not exercised. The bearing roller cageis a different diameter on each side. Be sure thebearing is installed so the large diameter side of thecage is facing the countershaft gear (Fig. 47). Thesmall diameter side goes in the bearing race.

REVERSE IDLER COMPONENTSInspect the idler gear, bearing, shaft, thrustwasher, wave washer and thrust plate. Replace thebearing if any of the needle bearing rollers are worn,

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chipped, cracked, flat-spotted, or brinnelled. Alsoreplace the bearing if the plastic bearing cage isdamaged or distorted.

Replace the thrust washer, wave washer, or thrustplate if cracked, chipped, or worn. Replace the idlergear if the teeth are chipped, cracked or worn thin.Replace the shaft if worn, scored, or the bolt threadsare damaged beyond repair. Replace the support seg-ment if cracked, or chipped and replace the idlerattaching bolts if the threads are damaged.Shift SocketInspect the shift socket for wear or damage.Replace the socket if the roll pin, or shift shaft boresare damaged. Replace the socket if the ball seat isworn, or cracked. Do not reuse the original shiftsocket roll pin. Install a new pin during reassembly.The socket roll pin is approximately 33 mm (1-1/4in.) long.Output Shaft And GeartrainInspect all of the gears for worn, cracked, chipped,or broken teeth. Also check condition of the bearingbore in each gear. The bores should be smooth andfree of surface damage. Discoloration of the gearbores is a normal occurrence and is not a reason forreplacement. Replace gears only when tooth damagehas occurred, or if the bores are brinnelled orseverely scored.Inspect the shaft splines and bearings surfaces.Replace the shaft if the splines are damaged or bear-ing surfaces are deeply scored, worn, or brinnelled.

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ASSEMBLYSealers are used at all case joints. Usea MoparGasket Maker for all case joints and Mopar siliconesealer or equivalent, for the input shaft bearingretainer. Apply these products as indicated in theassembly procedures.õ ö ÷ ø ù ú û ü ø ý þ ÿ � � � � � � � � � � � � ý � � ÿ � � � � � þ � ÿ � � � ÿ� þ � � ÿ ý þ û þ ÿ � � � � � � ÿ � � � � � � � � � � þ � � � � � � � � �� ! � � � � � � � � " � � � � � � � � � � � � � � � � �SYNCHRONIZER# $ % & ' & ( ) # * $ % + $ , * � - ( . $ + + * + # / ' . *$ + + * 0 1 . ' & ( � / * + - & 2 / % 3 & ' 4 * % � $ 1 $ . .2 3 5 . 6 7 5 0 8 3 5 � $ & 6 2 $ 5 + * ' & 7 5 % - �To assemble each synchro install the springs,struts and detent balls one at a time as follows:(1) Lubricate synchronizer components with MoparManual Transmission lubricant or equivalent.(2) Slide the sleeve part way onto the hub. Leaveenough room to install the spring in the hub and thestrut in the hub groove.(3) Install the first spring in the hub. Then installa strut over the spring. Be sure the spring is seatedin the spring bore in the strut.(4) Slide the sleeve onto the hub just far enough tohold the first strut and spring in place.(5) Place the detent ball in the top of the strut.Then carefully work the sleeve over the ball to holdit in place. Use a small flat blade screwdriver topress the ball into place while moving the sleeve overit.(6) Repeat the procedure for the remainingsprings, struts and balls. Tape or rubber band eachstrut and ball to temporarily secure as they areinstalled.(7) Verify synchro springs, struts and detent ballsare all in place (Fig. 48).

OUTPUT SHAFT& 3 � * ) . " 9 � � � � � � � � � � � � � � � � � � � ! � � � � � � � � � � � � � " 9 � � � � � � " � � � � � � � � � 9 � � � 8 � � � � � � " � : � � � � � � � 9 �" � � � � � � � � � � � � � � � � � � � �(1) Lubricate and install reverse gear needle bear-ing on shaft (Fig. 49). Slide bearing up against shoul-der on output shaft.(2) Install reverse gear over needle bearing (Fig.50).(3) Install brass synchro ring on reverse gear (Fig.51).

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(4) Assemble fifth-reverse synchro hub, sleeve,struts, springs and detent balls, if not previously done.n o p q r s t u s v w x y z w { | } ~ w ~ � � ~ � x x ~ { � � z w � x� � { � v z } ~ w ~ � � � { � w � } ~ y x x y z w { | } ~ w ~ � � | � � w x } ~ w| � { v } { | } ~ w x ~ � | } � s v w x y z w { | } ~ w x � w w � w y x } � � w � w z �q ~ w } � � w � w z x y z w | � � w x } ~ w | � { v } { | } ~ w x ~ � | } �(5) Start fifth-reverse synchro assembly on outputshaft splines by hand. Then seat synchro onto shaftwith a press and Cup 6310-1 (Fig. 52).t s q � u � � � x { v } ~ w x � v � ~ � { � y v � � � x } � w � � y � v w z� y } ~ } ~ w x � w w � w v { } � ~ w x | { � y v x } � � � � } y { v �

(6) Install new fifth-reverse hub snap ring (Fig.53) and verify the snap ring is seated.

(7) Install fifth gear synchro ring in synchro huband sleeve (Fig. 54).

(8) Install fifth gear bearing, spreading bearingonly enough to clear shoulder on output shaft (Fig.55). Verify bearing is properly seated.(9) Install fifth gear on shaft and onto bearing(Fig. 56).(10) Invert output shaft and set the shaft in Cup6310-1 so that fifth gear is seated on the tool (Fig.57).

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(11) Install first gear bearing on output shaft (Fig.57). Verify bearing is seated on shaft shoulder and isproperly joined.(12) Install first gear on shaft and over bearingwith synchro cone facing up (Fig. 58).

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(13) Install first gear synchro ring (Fig. 59).

(14) Assemble 1-2 synchro hub sleeve, springs,struts and detent balls.ò ó ô õ ö ÷ ø ù õ ú û ü ý þ ÿ � � � ú � � ú � � � � � ÿ û û û � � � � û� � ÿ � � û � � � � � � � � ÿ � ÷ � û ÿ � � û � � � ú û ÿ � � � ú � � ÿ û û û� ÿ � � � û � � � � ÿ � � û � � � � � û � � û � � � � � ú � ÿ ÿ � � û � � � ú ûÿ û û û � ÿ � � � � � � � � � ÿ � � û � � �(15) Start 1-2 synchro assembly on shaft by hand(Fig. 60). Verify synchro sleeve is properly positioned.

(16) Press 1-2 synchro onto output shaft usingsuitable size pipe tool and shop press (Fig. 61).ò ó ô õ ö ÷ ø ù ó � � � � ú û ÿ � � � ú � � � � � � � � � ÿ û û û � ÿ ú � �� ú û � ÿ � û � � � � � û ÿ ÿ û � � � � � � ú û ÿ ú � � � � õ ú û ÿ � � � ú � �� û � �� ! " # $ � % & ' ( � ) � � & "* + , - . / 0 1 2 3 . / 4 5 6 7 . 8 . - 5 19 + 6 : ;< + , - . / 0 1 2 3 .

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(17) Install interm ring.(18) Install new 1-2 synchro hub snap ring (Fig.62) and verfiy the snap ring is seated.

(19) Install second gear synchro ring in 1-2 syn-chro hub and sleeve (Fig. 63). Verify synchro ring isproperly seated.(20) Install synchro friction cone and synchro conein synchro ring.

(21) Install second gear needle bearing on shaft(Fig. 64).

(22) Install second gear onto shaft and bearing(Fig. 65). Verify second gear is fully seated on syn-chro components.

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(23) Install two-piece thrust washer (Fig. 66).Ensure washer halves are seated in shaft groove andthat washer lugs are seated in shaft lug bores.| } ~ � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � ��

(24) Start retaining ring around two-piece thrustwasher (Fig. 67). Ensure locating dimple is betweenthe thrust washer halves.(25) Seat thrust washer retaining ring with plasticmallet (Fig. 68).(26) Install third gear needle bearing on shaft (Fig.69).(27) Install third gear on shaft and bearing (Fig.70).

(28) Install third speed synchro ring on third gear(Fig. 71).(29) Assemble 3-4 synchro hub, sleeve, springs,struts and detent balls.(30) Start 3-4 synchro hub on output shaft splinesby hand (Fig. 72).� � � ~ � } | � ~ � � � � � � � � � � � � � � � � � � � � � � � � � � � � �� } � � � � � � � � � � � � � � � � � � � �� ~ � � � � � � � � � � � � � � � � � � � � � � � � � � � � � ��

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(31) With the lug on the ring aligned with the sloton the synchro, press 3-4 synchro assembly onto out-put shaft with shop press and suitable size pipe tool(Fig. 73).Ñ Ò Ó Ô Õ Ö × Ø Ù Ú Û Ü Ú Ý Þ Ý Ú ß à Ü á â Ø ã Ù × ß ã Ú Û ß ß á Û Ý á Ûã Ü Ø ä Û Ø ã Ý ß ã ã Þ â × Ú å Þ Û Ü ß á Û Ù ß à Û Ø Ù Û Þ à æ Û Ü Ú ã Ü Ø ä Ûã Ý × Þ à Ú ã ç

(32) Install new 3-4 synchro hub snap ring (Fig.74) and verify snap ring is seated.

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(33) Verify position of synchro sleeves before pro-ceeding with assembly operations (Fig. 75). Groovedside of 3-4 sleeve should be facing forward. First gearside of 1-2 sleeve should be facing first gear. Taperedside of fifth-reverse sleeve should be facing forward.

REVERSE IDLER ASSEMBLY(1) Lubricate idler components with Mopar Man-ual Transmission lubricant or equivalent.(2) Slide idler gear bearing on shaft (Fig. 76).Bearing fits either way on shaft.(3) Slide gear onto shaft. Side of gear with recessgoes to rear (Fig. 76).(4) Place first lock ball in dimple at rear end ofidler shaft (Fig. 76). Hold ball in place with petro-leum jelly.(5) Slide rear thrust washer onto shaft and overlock ball (Fig. 77).(6) Install snap ring in groove at rear of shaft (Fig.77).(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 slidewasher up against gear and over lock ball (Fig. 78).(9) Install wave washer, flat washer and remain-ing snap ring on idler shaft (Fig. 78). Verify snapring is seated.

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SHIFT SHAFT AND BUSHINGS/BEARINGSInspect shift shaft bushing and bearing for damageand replace if necessary.(1) Locate a bolt that will thread into the bushingwithout great effort.(2) Thread the bolt into the bushing, allowing thebolt to make its own threads in the bushing.(3) Attach a slide hammer or suitable puller to thebolt and remove bushing.(4) Use the short end of Installer 8119 to installthe new bushing.(5) The bushing is correctly installed if the bush-ing is flush with the transmission case.(6) To replace the bearing locate a bolt that willthread into the bearing without great effort.

(7) Thread the bolt into the bearing as much aspossible.(8) Attach a slide hammer or suitable puller to thebolt and remove the bearing.(9) Use the short end of Installer 8119 to installthe new bearing.(10) The bearing is correctly installed if the bear-ing is flush with the transmission case.DETENT PLUNGER BUSHINGInspect detent plunger bushings for damage andreplace if necessary.X Y Z [ \ Z ] ^ _ ^ ` ^ a ` b c d a e ^ f g d h ] i a e h j f ^ i a h ` j c c ^ _ ` kj h b ^ l i m i l _ ^ b ` ] n Z ] ^ h b j l ^ g ^ ` o ^ ^ a ` ] ^ ` o k g d h ] pi a e h o ] ^ a l k f f ^ l ` c q i a h ` j c c ^ _ l k a ` j i a j a k i c m ^ ^ _] k c ^ n r k a k ` j ` ` ^ s b ` ` k i a h ` j c c ` ] ^ g d h ] i a e h o i ` ]j a q ` ] i a e k ` ] ^ f ` ] j a ` ] ^ h b ^ l i m i ^ _ ` k k c k f ` ] i h k i c] k c ^ s j q g ^ l k s ^ f ^ h ` f i l ` ^ _ n(1) Using the long end of Installer 8119, drive thedetent bushings through the outer case and into theshift shaft bore.(2) Remove the bushings from the shift shaft bore.(3) Install a new detent plunger bushing on thelong end of Installer 8118.

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(4) Start the bushing in the detent plunger bore inthe case.(5) Drive the bushing into the bore until the toolcontacts the transmission case.(6) Install a new detent plunger bushing on theshort end of Installer 8118.(7) Start the bushing in the detent plunger bore inthe case.(8) Drive the bushing into the bore until the toolcontacts the transmission case.GEARTRAIN ASSEMBLY(1) Install Adapter 6747-1A on input shaft hub ofFixture 6747 (Fig. 79).

(2) Install input shaft in fixture tool. Make sureAdapter 6747-1A is positioned under shaft as shown(Fig. 80).(3) Install pilot bearing in input shaft (Fig. 80).¨ © ª « ¬ ª ® ¯ ° ± ® ² ³ ´ ® µ ° ¶ ² ´ · ® ¸ ¹ ° º » ¼ ° ´ ´ ® ¯ ½ ¸ ¶ ¶± ° ¸ ½ ® ´ ® ¹ » ² ® ¯ ´ ² ¼ ¸ ¹ ± ´ ® ° º µ ¾ ´ ¯ ¸ ³ ´ ¿

(4) Install fourth gear synchro ring on input shaft(Fig. 81).

(5) Adjust height of idler gear pedestal on assem-bly fixture (Fig. 82). Start with a basic height of 18.4cm (7-1/4 in.). Final adjustment can be made aftergear is positioned on pedestal.(6) Install assembled output shaft and geartrain ininput shaft (Fig. 83). Carefully rotate output shaftuntil the 3-4 synchro ring seats in synchro hub andsleeve.

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(7) Install Adapter 6747-2A on front bearing hub ofcountershaft. The adapter has a shoulder on one sidethat goes towards the countershaft.(8) Slide countershaft (and adapter) into fixtureslot. Verify countershaft and output shaft gears arefully meshed with the mainshaft gears (Fig. 84).(9) Check alignment of countershaft and outputshaft gear teeth. Note that gears may not align per-fectly. A difference in height of 1.57 to 3.18 mm (1/16to 1/8 in.) will probably exist. This difference will notinterfere with assembly.

(10) Position reverse idler in support cup of assem-bly fixture (Fig. 85). Ensure idler gear is properlymeshed and aligned with shaft gear teeth and thatbolt holes are facing out and not toward geartrain.Adjust pedestal up or down if necessary. Also be surethat short end of idler shaft is facing up as shown.

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(11) Assemble 1-2 and fifth reverse-shift forks (Fig.86). Arm of fifth-reverse fork goes through slot in 1-2fork.

(12) Install assembled shift forks in synchrosleeves (Fig. 87). Verify forks are properly seated insleeves.

ADAPTER HOUSING(1) Install rear bearing in adapter housing. Usewood hammer handle or wood dowel to tap bearinginto place.(2) Position rear bearing retainer in adapter hous-ing (Fig. 88).

(3) Apply Mopar Gasket Maker or equivalent, tothreads, bolt shanks and under hex heads of bearingretainer bolts.

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(4) Apply liberal quantity of petroleum jelly tocountershaft rear bearing and bearing race.(5) Install countershaft rear bearing in bearingrace (Fig. 88).h i j k l m n o p q r s t q u v q w x t y q z { x | q u q t r { z q } ~ u v qt } w w q t t q u x { � q t ~ x � q r u v q � } s � u q t r v x ~ u x � z u v q r | x w wz { x | q u q t r { z q ~ x � q r u v q t x � q x � z v } s r { � y �(6) Apply extra petroleum jelly to hold counter-shaft rear bearing in place when housing is installed.(7) Apply light coat of petroleum jelly to shift shaftbushing/bearing in adapter housing.(8) Install adapter housing on geartrain.(9) Install rear bearing snap ring on output shaft(Fig. 89).

(10) Lubricate lip of new rear seal (Fig. 90) withMopar Door Ease or transmission fluid.(11) Install new rear seal in adapter housing borewith Installer C-3860-A. Verify seal is seated in hous-ing bore (Fig. 90).(12) Slide reverse idler shaft support straight intothe housing.(13) Install reverse idler shaft support bolt andidler shaft bolt (Fig. 91). Tighten bolts to 19-25 N·m(14-18 ft. lbs.).

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SHIFT SHAFT, SHAFT LEVER AND BUSHING ANDSHIFT SOCKET(1) Verify that all synchro sleeves are in Neutralposition (centered on hub).® ¯ ° ± ² ³ ´ µ ± ¶ · ¸ ¹ º » ¼ ½ ¾ ¼ ¼ ¾ ¿ » ¼ À » Á ¶ ¹ ¿ ¼ ½ Â ¼ ¸ º Ã Ã Ä ·¾ » ´ · Â ¸ ¹ º Ã Å ¿ ¼ ¾ ¸ ¾ ¿ » Æ ¿ ¹ º ¼ ¼ · ½ Ä Ã À Ç ³ ¸ ¶ · ¹ È ¾ ¼ · ¸ ¶ ·¶ ¿ Â ¼ ¾ » É ¼ Ê ¼ ¶ ¾ Æ ¸ Æ ¿ ¹ Ë ¼ º » Ì É · º ¹ ¼ Á º » Ä · Ì º ½ º É · ÌÌ Â ¹ ¾ » É ¾ » ¼ ¸ º Ã Ã º ¸ ¾ ¿ » ¿ Æ ¸ ¶ · ¸ È ¿ ¶ ¿ Â ¼ ¾ » É ¼ Ç(2) Install 3-4 shift fork in synchro sleeve (Fig. 92).Verify that groove in fork arm is aligned with groovesin 1-2 and fifth-reverse fork arms as shown.

(3) Slide the end of shift shaft with shaft detentnotches through 3-4 shift fork.(4) Assemble shift shaft shift lever and bushing(Fig. 93). Be sure slot in bushing is facing up and rollpin hole for lever is aligned with hole in shaft.(5) Install assembled lever and bushing on shiftshaft (Fig. 94).(6) Slide shift shaft through shift forks (Fig. 95)and into shift lever opening in rear housing (Fig. 96).(7) Align shift socket with shaft and slide shaftthrough socket and into shift shaft bearing in rearhousing (Fig. 97).

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(8) Rotate shift shaft so detent notches in shaft arefacing the TOP of the transmission housing.� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � ! � � � � � � � � � � " � # � � � � � � � � � � � � � � � � � � � � � � � � � $� � � � � � � � � � � � � � � � � � � � � � � � � � �(9) Select correct new roll pin for shift shaft lever(Fig. 98). Shaft lever roll pin is approximately 22 mm(7/8 in.) long. Shift socket roll pin is approximately33 mm (1-1/4 in.) long.(10) Align roll pin holes in shift shaft, lever andbushing. Then start roll pin into shaft lever by hand(Fig. 99).(11) Seat shaft lever roll pin with pin punch (Fig.100).

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(12) Verify that lock pin slot in lever bushing ispositioned as shown (Fig. 100).

(13) Align roll pin holes in shift socket and shiftshaft. Then start roll pin into shift shaft by hand(Fig. 101).

(14) Seat roll pin in shift socket with pin punch.Roll pin must be flush with socket (Fig. 102).(15) Verify that notches in shift fork arms arealigned (Fig. 103). Realign arms if necessary.(16) Rotate shift lever and bushing downward toexpose detent bore in the lever.

(17) Install detent spring then the ball into thedetent bore (Fig. 104) and hold the ball in the lever.Then rotate the lever upward into the fork armnotches.` a b c d e f g h i j k f l f m l n o p p h q q f o l f k h m l r f i s g t o g u qn f i s g f v g s w f f k h m x y

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FRONT HOUSING AND INPUT SHAFT BEARINGRETAINER(1) Install reverse blocker, retainter and retainerbolt in front housing.(2) If previously removed, input shaft bearing infront housing (Fig. 105). Install snap ring and useplastic mallet to seat bearing. Bearing goes in fromfront side of housing only.

(3) Apply liberal quantity of petroleum jelly tocountershaft front bearing. Then insert bearing infront housing race (Fig. 105). Large diameter side ofbearing cage goes toward countershaft (Fig. 106).Small diameter side goes toward bearing race inhousing.

(4) Reach into countershaft front bearing with fin-ger, and push each bearing roller outward againstrace. Then apply extra petroleum jelly to hold rollersin place. This avoids having rollers becoming dis-placed during housing installation.

(5) Apply small amount of petroleum jelly to shiftshaft bushing in front housing.(6) Apply 1/8 in. wide bead of Mopar GasketMaker or equivalent, to mating surfaces of front andrear housings (Fig. 107).

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(7) Have helper hold rear housing and geartrain inupright position. Then install front housing on rearhousing and geartrain.(8) Work front housing downward onto geartrainuntil seated on rear housing.ç è é ê ë ì í î ë ï ð ñ ò ï ó ô õ ð ñ ô ö ÷ ø õ ù ú ø û û õ ô ð ÷ ò ü ð ô õ ð ñ òó ò ü ó ñ ô ö ÷ ø õ ù ý ò ø ð ñ ò ó ð ñ ò ÷ ñ ø ï ð þ ô ÿ � ô õ ò õ ð ÷ ü ó ò õ ô ð ø õí ò ö ð ó ü û ý ô ó ô õ ò ô ó ÿ ô ó ò þ ô ÿ � ô õ ò õ ð ÷ ü ó ò ÿ ø ÷ �ü û ø ù õ ò � � � ô õ ô ð ï ô ó þ ò ð ñ ò ï ó ô õ ð ñ ô ö ÷ ø õ ù ø õ ð ô � û ü þ ò �ê ñ ø ÷ ú ø û û ô õ û � ó ò ÷ ö û ð ø õ � ü ÿ ü ù ò � þ ô ÿ � ô õ ò õ ð ÷ �(9) Tap rear housing alignment dowels back intoplace with hammer and pin punch. Both dowelsshould be flush fit in each housing. Have helper holdtransmission upright while dowels are tapped backinto place.(10) Place transmission in horizontal position.(11) Apply Mopar Gasket Maker or equivalent tohousing attaching bolts. Apply sealer material sealerto underside of bolt heads and to bolt shanks andthreads (Fig. 108).(12) Install and start housing attaching bolts byhand (Fig. 108). Then tighten bolts to 34 N·m (25 ft.lbs.).

(13) Install shift shaft bushing lock bolt (Fig. 109).Apply Mopar Gasket Maker or equivalent, to boltthreads, shank and underside of bolt head beforeinstallation.í ì ê � î ê ñ ø ÷ ø ÷ ü ÷ � ò þ ø ü û � ô û ð ü õ � þ ü õ õ ô ð � ò ÷ ö � ÷ ð ø �ð ö ð ò � ú ø ð ñ ü õ � ô ð ñ ò ó � ô û ð �

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(14) Lubricate then install shift shaft detentplunger in housing bore. Lubricate plunger with Val-voline Dura Blendt semi-synthetic/synthetic greaseor equivalent. Verify plunger is fully seated indetent notch in shift shaft.(15) Install detent spring inside plunger.(16) Install plug on detent spring and compressspring. Then drive detent plug with Installer 8123into transmission case until plug seats.(17) Install backup light switch (Fig. 110).

(18) Install input shaft snap ring (Fig. 111).

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(19) Install new oil seal in front bearing retainerwith Installer 6448 (Fig. 112).

(20) Apply bead of Mopar silicone sealer or equivalentto flange surface of front bearing retainer (Fig. 113).

(21) Align and install front bearing retainer overinput shaft and onto housing mounting surface (Fig.114). Although retainer is one-way fit on housing, besure bolt holes are aligned before seating retainer.7 8 9 : ; : < = > ? @ < A = @ B C @ ? D @ E = F < E G @ E ? B < = H F = = F A <I B = @ A F C J @ @ K G A C @ B < K = C A E F < L @ B ? F < D ? @ E B F < @ ? F =B C F D < @ K M F E G A F C J @ @ K G A C @ N

(22) Install and tighten bearing retainer bolts to9-14 N·m (7-10 ft. lbs.) (Fig. 115).

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SHIFT TOWER AND LEVER(1) Apply petroleum jelly to ball end of shift leverand interior of shift socket.(2) Shift the transmission into third gear.(3) Align and install shift tower and lever assem-bly (Fig. 116). Be sure shift ball is seated in socketand the offset in the tower is toward the passengerside of the vehicle before installing tower bolts.(4) Install shift tower bolts (Fig. 117). Tightenbolts to 8.5 N·m (75.2 in. lbs.).

(5) Fill transmission to bottom edge of fill plughole with Mopar Transmission Lubricant.(6) Install and tighten fill plug to 34 N·m (25 ft.lbs.).(7) Check transmission vent. Be sure vent is openand not restricted.

INSTALLATION(1) Install clutch housing on transmission andtighten housing bolts to 46 N·m (34 ft. lbs.).(2) Lubricate contact surfaces of release fork pivotball stud and release fork with high temp grease.(3) Install release bearing, fork and retainer clip.(4) Position and secure transmission on transmis-sion jack.(5) Lightly lubricate pilot bearing and transmissioninput shaft splines with Mopar high temp grease.(6) Raise transmission and align transmissioninput shaft and clutch disc splines. Then slide trans-mission into place.(7) Install and tighten clutch housing-to-enginebolts to:Be sure the housing is properly seatedon engine block before tightening bolts.• Tighten 3/8” diameter bolts to 37 N·m (27ft.lbs.).• Tighten 7/16” diameter bolts to 58 N·m (43ft.lbs.).• Tighten M12 bolts to 75 N·m (55 ft.lbs.).(8) Be sure transmission is in first or third gear.(9) Install crossmember and tighten crossmember-to-frame bolts to 41 N·m (31 ft. lbs.).(10) Install fasteners to hold rear cushion andbracket to transmission. Then tighten transmission-to-rear support bolts/nuts to 54 N·m (40 ft. lbs.).(11) Remove support stands from engine andtransmission.(12) Install and connect crankshaft position sensor.(13) Install transfer case.(14) Install rear propeller shaft slip yoke to trans-mission or transfer case output shaft if equipped.(15) Install rear propeller shaft with referencemarks aligned (Fig. 118).

(16) Install and tighten propeller shaft U-jointclamp bolts to 19 N·m (170 in. lbs.).

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(17) Align marks on front propeller shaft, axle andtransfer case yokes.(18) Install and tighten propeller shaft U-jointclamp bolts to 19 N·m (170 in. lbs.).(19) Install slave cylinder in clutch housing.(20) Install skid plate, if equipped and tightenbolts to 42 N·m (31 ft. lbs.). Tighten stud nuts to 17N·m (150 in. lbs.).(21) Fill transmission and transfer case ifequipped, with recommended lubricants. Refer to the

Lubricant Recommendation sections of the appropri-ate component for correct fluid.(22) Lower vehicle.(23) Install nuts on two M6X1.0 bolts and threadthe bolts into the threaded holes at the base of theshift lever.(24) Tighten the nuts equally until the shift leverwill slide over the shift tower stub shaft.(25) Install the floor console and shift boot.

SPECIFICATIONS TORQUE SPECIFICATIONS° ± ² ³ ´ µ ¶ · µ ¸ ¹ ¹ º » ¼ ½ ¾ ¿ À Á ¾ µ Â ¾ ¿ À Á ¾Ã Ä Å Æ Ç È É Ê Å Ë Ì Í Î Ï Ê Ä Æ Ë Ð Ñ Ò Ó Ô Ñ Õ Ò Ñ Ð ÒÃ Ö Ê Ë Ë × Ø × Ù Ø Ö Ú Ê Û Ö Ü × Ø Ï Ê Ä Æ Ë Ó Ô Ò Ý Ð Ñ Ñ Ò Ð Ð ÒÃ Ö Ê Ë Ë × Ø × Ù Ø Ö Ú Ê Þ Í Ë Å Ä Ü Æ Ê Ö ß Å Æ Ë Ð Ñ Ò Ó Ô Ñ Õ Ò Ñ Ð Òà Ö Ü Ì Í á Û Ì Ä Ä â Ä Å Î ã Ò ä Ý Ô Ñ Ò ä Õ ÒÛ Ö Ê Í Æ Ú Ê å Ø Ü Ö É Ê Å Ë Ì Í Î Ï Ê Ä Æ Ë æ Õ Ò æ Ð ä ä Ò ä Ó ÒÛ Ö Ê Í Æ Ï Ø Ü Ö Ì Í Î å Ø Æ Ü Ì Í Ø Ö Ï Ê Ä Æ Ë ã Ò Ô Ñ Ý Ò ç ç Õ Ò Ô ä ÑÞ è Ä Ø Ö é È Ü ê Æ Ï Ê Ä Æ Ë Ô ã Ò ä Ð Ô Ñ Ò Ô ç Òå Ø Ü Ö Ï Ø Ü Ö Ì Í Î å Ø Æ Ü Ì Í Ø Ö Ï Ê Ä Æ Ë æ Õ Ò æ Ð ä ä Ò ä Ó Òé È Ì ê Æ Ú Ê ë Ø Ö Ï Ê Ä Æ Ë Ý Ò Ô Õ Ð Ò Ý Ó ä Ò ç çé Ä Ü ì Ø Ã í Ä Ì Í è Ø Ö ß Å Æ Ë ä æ Ô Ý ÒÚ Ö Ü Í Ë ê Ø Ö Ã Ü Ë Ø ß Å Æ Ë Ñ Ý æ Ð Òî Ò ï Ê Ì Í Æ Ã Ä Ü × ð Ï Ê Ä Æ Ë Ô ã Ô Ñ ÒSPECIAL TOOLS

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VEHICLE SPEED SENSORDESCRIPTIONThe 3-wire Vehicle Speed Sensor (VSS) is locatedon the speedometer pinion gear adapter. If equippedwith 4WD, this adapter is located on the extensionhousing of the transfer case (drivers side). Ifequipped with 2WD, this adapter is located on theleft side of the transmission extension housing.OPERATIONThe VSS is a 3-circuit (3–wire), magnetic, hall-ef-fect sensor.The 3 circuits are:

• A 5-volt power supply from the Powertrain Con-trol Module (PCM).• A ground is provided for the sensor though alow-noise sensor return circuit in the PCM.• An input to the PCM is used to determine vehi-cle speed and distance traveled.

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The speed sensor generates 8 pulses per sensorrevolution. These signals, in conjunction with aclosed throttle signal from the throttle position sen-sor, indicate a closed throttle deceleration to thePCM. When the vehicle is stopped at idle, a closedthrottle signal is received by the PCM (but a speedsensor signal is not received).Under deceleration conditions, the PCM adjuststhe Idle Air Control (IAC) motor to maintain adesired MAP value. Under idle conditions, the PCMadjusts the IAC motor to maintain a desired enginespeed.REMOVALThe Vehicle Speed Sensor (VSS) is located on thespeedometer pinion gear adapter. If equipped with4WD, this adapter is located on the transfer caseextension (left side) (Fig. 119). If equipped with 2WD,this adapter is located on the extension housing ofthe transmission (left side).

(1) Raise and support vehicle.(2) Disconnect electrical connector from sensor bypushing slide tab (Fig. 119). After slide tab has beenpositioned, push in on secondary release lock (Fig.119) on side of connector and pull connector fromsensor.(3) Remove sensor mounting bolt (Fig. 120).(4) Remove sensor (pull straight out) from speed-ometer pinion gear adapter (Fig. 120). Do not removegear adapter from transmission.INSTALLATION(1) Clean inside of speedometer pinion gearadapter before installing speed sensor.(2) Install sensor into speedometer gear adapterand install mounting bolt. Before tightening bolt, ver-ify speed sensor is fully seated (mounted flush) tospeedometer pinion gear adapter.(3) Tighten sensor mounting bolt to 2.2 N·m (20 in.lbs.) torque.(4) Connect electrical connector to sensor.

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TJ MANUAL - NV3550 21 - 67VEHICLE SPEED SENSOR (Continued)

manual - nv3550

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