Dodge Dakota (R1). Manual - part 596

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 counter-
shaft end-play. This gives the amount of shims nec-
essary 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 N·m (21.4 ft. lbs.). Ver-
ify 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 in.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 coun-
tershaft pre-load.

(12) Lubricate

then

install

shift

shaft

detent

plunger in housing bore (Fig. 87). Lubricate plunger
with petroleum jelly or gear lubricant. Be sure
plunger is fully seated in detent notch in shift
shaft.

(13) Install detent spring inside plunger (Fig. 87).
(14) 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.

(15) Install backup light switch (Fig. 88).
(16) Install input shaft snap ring (Fig. 89).
(17) Install new oil seal in front bearing retainer

with Installer 6448 (Fig. 90).

(18) Apply bead of Mopar® Silicone Sealer or

equivalent to flange surface of front bearing retainer.

Fig. 85 HOUSING ATTACHING BOLTS

1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)

Fig. 86 SHIFT SHAFT BUSHING LOCK BOLT

1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET

Fig. 87 SHIFT SHAFT DETENT PLUNGER

1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER

21 - 28

MANUAL - NV1500

MANUAL - NV1500 (Continued)

(19) Align and install front bearing retainer over

input shaft and onto housing mounting surface (Fig.
91). 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.

(20) Install and tighten bearing retainer bolts to

29 N·m (21.4 ft. lbs.) (Fig. 92).

Fig. 88 BACKUP LIGHT SWITCH

1 - BACKUP LAMP SWITCH

Fig. 89 INPUT SHAFT SNAP RING

1 - INPUT SHAFT SNAP RING

Fig. 90 BEARING RETAINER OIL SEAL

1 - SPECIAL TOOL
6448
2 - FRONT BEARING RETAINER

Fig. 91 INPUT SHAFT BEARING RETAINER

1 - BEARING RETAINER
2 - OIL FEED

Fig. 92 INPUT SHAFT BEARING RETAINER BOLTS

1 - BOLTS (5)
2 - BEARING RETAINER

MANUAL - NV1500

21 - 29

MANUAL - NV1500 (Continued)

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 assem-

bly (Fig. 93). 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. 94) and tighten

bolts to 8.5 N·m (75.2 in. lbs.).

(5) Fill transmission to bottom edge of fill plug

hole with Mopar® Transmission.

(6) Install and tighten fill plug to 34 N·m (25 ft.

lbs.).

(7) Check transmission vent. Be sure vent is open

and not restricted.

INSTALLATION

NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.

(1) Apply light coat of Mopar® high temperature

bearing grease to contact surfaces of following com-
ponents:

• input shaft splines.

• release bearing slide surface of front retainer.

• release bearing bore.

• release fork.

• release fork ball stud.

• propeller shaft slip yoke.
(2) Apply sealer to threads of drain plug and

install plug in case.

(3) Mount transmission on jack and position trans-

mission under vehicle.

(4) Raise transmission until input shaft is centered

in clutch disc hub.

(5) Move transmission forward and start input

shaft in clutch disc and pilot bushing.

(6) Work transmission forward until seated against

engine. Do not allow transmission to remain unsup-
ported after input shaft has entered clutch disc.

(7) Install and tighten transmission-to-engine bolts

to 108 N·m (80 ft. lbs.).

(8) Install clutch slave cylinder.
(9) Install transmission dust shield.
(10) Install starter.
(11) Connect backup light switch wires.
(12) Fill transmission with recommended lubri-

cant. Correct fill level is bottom edge of fill plug hole.

(13) Install shift tower and lever assembly. Tighten

shift tower bolts to 7-10 N·m (5-7 ft. lbs.).

(14) Position transmission harness wires in clips

on shift cover.

(15) Install transmission mount on transmission or

rear crossmember.

(16) Install rear crossmember.
(17) Remove transmission jack and engine support

fixture.

(18) Align and install propeller shaft.
(19) Lower vehicle.
(20) Install the shift lever extension onto the shift

tower and lever assembly.

(21) Install shift boot.
(22) Install floor console. Refer to 23 Body for pro-

cedures.

(23) Connect battery negative cable.

Fig. 93 SHIFT TOWER

1 - SHIFT TOWER AND LEVER ASSEMBLY
2 - SHIFT SOCKET
3 - SEAL

Fig. 94 SHIFT TOWER BOLT

1 - SHIFT TOWER AND LEVER ASSEMBLY

21 - 30

MANUAL - NV1500

MANUAL - NV1500 (Continued)

SPECIFICATIONS

SPECIFICATIONS - NV1500

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Back up Lamp Switch

Coutershaft Bearing Shim

Cap

Bearing Retainer - Front

Bearing Retainer - Rear

Drain/Fill Plug

Shift Shaft Lock Bolt

Idler Shaft Bolts - M8

Idler Shaft Bolts - M10

Shift Tower Bolts

120

SPECIAL TOOLS

MANUAL - NV1500

Installer, Seal C-3995-A

Remover, Bushing 6957

Installer, Bushing 8160

Driver, Bearing Race C-4656

Installer, Seal 6448

Handle C-4171

MANUAL - NV1500

21 - 31

MANUAL - NV1500 (Continued)

Content .. 594 595 596 597 ..