Dodge Dakota (ND). Manual - part 902

PULLEY

REMOVAL

CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new
pulley must be installed if removed.

1. Remove the power steering pump assembly, (Refer

to 19 - STEERING/PUMP - REMOVAL).

2. Remove the pulley (2) from the pump (1) using

(OTC

7185) power steering pulley removal tool (3)

or equivalent.

INSTALLATION

CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new
pulley must be installed if removed.

1. Replace the pulley if it’s bent, cracked, or loose.

2. Install the pulley (2) on the pump (1) using (OTC

7771) power steering pulley installation tool (3) or
equivalent making sure it is flush with the end of
the shaft. Ensure the tool and pulley remain
aligned with the pump shaft.

3. Install the power steering pump assembly, (Refer to

19 - STEERING/PUMP - INSTALLATION).

4. Run engine until warm (5 min.) and note any belt

chirp. If chirp exists, move pulley outward approxi-
mately 0.5 mm (0.020 in.). If noise increases, press
on 1.0 mm (0.040 in.). Be careful that pulley
does not contact mounting bolts.

19 - 48

PUMP

TRANSMISSION AND TRANSFER CASE

TABLE OF CONTENTS

page

MANUAL TRANSMISSION-GETRAG 238

. . . . . . . 1

AUTOMATIC TRANSMISSION 42RLE -

ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . 71

AUTOMATIC TRANSMISSION 42RLE - SERVICE

INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 242

AUTOMATIC TRANSMISSION 545RFE -

ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 416

AUTOMATIC TRANSMISSION 545RFE -

SERVICE INFORMATION . . . . . . . . . . . . . . . . . 681

TRANSFER CASE - ELECTRICAL

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 826

TRANSFER CASE - NV233

. . . . . . . . . . . . . . . . 874

TRANSFER CASE - NV244

. . . . . . . . . . . . . . . . 915

MANUAL TRANSMISSION-GETRAG 238

TABLE OF CONTENTS

page

MANUAL TRANSMISSION-GETRAG 238

DIAGNOSIS AND TESTING

MANUAL TRANSMISSION - G56

. . . . . . . . . . . 1

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . 4

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 29

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 63

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . 66

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . 67

MANUAL TRANSMISSION-GETRAG 238

DIAGNOSIS AND TESTING

MANUAL TRANSMISSION - GETRAG 238

LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or incorrect lubricant level
check.

Rear transmission leaks will be from the oil seals or component mating surfaces.

Front transmission leaks will be from the front input shaft retainer seal. Lubricant may drip from the clutch housing
after extended operation. If leak is severe, it may contaminate the clutch disc.

Lubricant level check can only be made when the vehicle is level and allowing the lubricant to settle for a minute
before checking. This will ensure an accurate check and avoid an under or overfill condition.

HARD SHIFTING

Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants. This will cause noise,
excessive wear, internal bind, and hard shifting. Substantial lubricant leaks can result in gear, shift rail, synchro, and
bearing damage. The first indications of component damage is usually hard shifting and noise.

Shift component damage, clutch adjustment, worn pressure plate or disc are also causes of increased shift effort. If
clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchronizer rings can cause

TRANSMISSION AND TRANSFER CASE

21 - 1

gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend
to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear-in.

TRANSMISSION NOISE

Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is
audible, but generally only at extreme speeds.

Severe, highly audible transmission noise is generally the initial indicator of a lubricant problem. Insufficient,
improper or contaminated lubricant will promote rapid wear of gears, synchronizer rings, shift rails, forks and bear-
ings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.

REMOVAL

1. Disconnect battery negative cable.

2. Shift transmission into Neutral.

3. Remove the upper shift lever boot (2). (Refer to 23

- BODY/INTERIOR/SHIFT BOOT - REMOVAL)

4. Remove floor console (3). (Refer to 23 - BODY/IN-

TERIOR/FLOOR CONSOLE - REMOVAL)

5. Remove the shift lever extension (1) from the shift

tower and lever assembly.

6. Remove the screws holding the lower shift lever

boot assembly to the floorpan and remove the
lower shift boot assembly.

7. Through the hole in the floorpan, remove the bolts

(2) holding the shift tower (1) to the transmission.

8. Remove the shift tower (1) from the transmission.

9. Raise vehicle.

10. Remove skid plate, if equipped (4WD).

11. If transmission will be disassembled for repair, remove drain plug and drain lubricant from transmission.

12. Mark propeller shafts and companion flange for assembly reference.

13. Disconnect and remove propeller shafts.

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MANUAL TRANSMISSION-GETRAG 238

14. Disconnect and remove exhaust system Y-pipe. Then disconnect and lower remaining exhaust pipes for clear-

ance as necessary.

15. Disconnect backup light switch wires.

2WD

1. Remove bolts/nuts attaching transmission to rear mount.

2. Support transmission with a transmission jack. Secure transmission to jack with safety chains.

3. Remove rear crossmember.

4. Remove bolts attaching clutch slave cylinder to clutch housing. Then move cylinder aside for working clearance.

5. Remove starter.

6. Remove transmission dust shield.

7. Remove transmission harness wires from clips on transmission shift cover.

8. Lower transmission slightly.

9. Remove bolts attaching transmission to engine.

CAUTION: Do not remove structural dust cover from enigne block. If cover is removed clutch housing and
cover must be aligned with the engine.

10. Slide transmission and jack rearward until input shaft clears clutch disc.

11. Lower transmission jack and remove transmission from under vehicle.

4WD

1. Support engine with adjustable safety stand.

2. Remove transfer case. (Refer to 21 - TRANSMISSION/TRANSAXLE/TRANSFER CASE - REMOVAL)

3. Remove bolts/nuts attaching transmission to rear support.

4. Remove crossmember bolts/nuts and remove crossmember.

5. Support transmission with transmission jack. Secure transmission to jack with safety chains.

6. Remove transmission harness from retaining clips on transmission shift cover.

7. Remove clutch slave cylinder splash shield, if equipped.

8. Remove clutch slave cylinder attaching nuts. Move cylinder aside for working clearance.

9. Remove starter.

10. Remove transmission splash shield.

11. Lower transmission slightly.

12. Remove bolts attaching transmission to engine.

13. Move transmission rearward until input shaft clears clutch disc.

14. Lower transmission and remove it from under vehicle.

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