2003 NV3500 Service Manual

DR

DR

TR ANS MISSI ON AND TR ANSFER CASE

21 - 1

T R A N S M IS IO N A N D T R A N S F E R C A S E 2 1 - 1 TABLE OF CO NTENTS TABLE O F CO N TEN TS

TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page

MANUAL TRANSMISSION - NV3500 ..... .....1 MANUAL TRANSMISSION - NV4500 . . . . . . . . . . 42 MANUAL TRANSMISSION - NV5600 . . . . . . . . . . 87 AUTOMATIC TRANSMISSION - 46RE . . . . . . . . 129 AUTOMATIC TRANSMISSION - 48RE . . . . . . . . 310

page

. . 488 . . . . . 591 591 . . . . . 623 623 . . . . . 658 658 . . . . . 687 687

AUTOMATIC TRANSMISSION - 45RFE/545RFE

TRANSFER CASE - NV241 GENII . . . . . . TRANSFER CASE - NV271 . . . . . . . . . . . TRANSFER CASE - NV243 . . . . . . . . . . . TRANSFER CASE - NV273 . . . . . . . . . . .

M A N U A L T R A N S M IS IO N - N V 3 5 0

MANUAL TRANSMISSION - NV3500 TABL E OF CONTENTS page

page

MANUAL TRANSMISSION - NV3500 DESC DE SCRI RIPT PTIO ION N . . . . . . .. . . . . . .. . . . . . .. . . . .1 OPER OP ERA ATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAG DI AGNO NOSI SIS S AND AND TES TESTI TING NG . . . . . .. . . . . . .. . .3 REMO MOV VAL .............................3 DISA DI SASS SSEM EMBL BLY Y ..........................4

CLEANI CLEA NING NG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 15 INSP IN SPEC ECTI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . . 15  ASS  A SSEM EMBL BLY Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INST IN STAL ALLA LATI TION ON . . . . . . . . . . . . . . . . . . . . . . . . . 38 SPEC SP ECIF IFIC ICA ATI TION ONS S . . . . . . . . . . . . . . . . . . . . . . . 39 SPEC SP ECIA IAL L TOO TOOLS LS . . . . . . . . . . . . . . . . . . . . . . . 40 40

MNDswtiEaTVAnShhtCe3fNRimt5tIreUPas0nThgAsIeOmfauLNrilsyoTivosenRyrdiArcsihvNareonmrSiazenMdgieuI.mSTa-dhnuetIaytOrl5tnN-rssapmnes-imd,ioscnoins- istseTnphnohrplTigiesinfunhhttie,eanldfsatdhslvturpoaetihefvtthrsehohdetreauoantgsftrtdrtehahalinnestschslmtcmedsoietnismfasomieiuripesoercnashntdregttodiginhefcceaaptouroulsatuntrarhtsperhegoasetcfihassrttlppaaruaoienftntbnncsdhydm.iniTigmssgehoati.veoursinArnngmtgcaeoogdtutvehhandieest--. aT vh ae ltarb lne s min st w io n a gn e a rfo cua s-ew hc o n sl id trsiv o f ct ow fiag lu rma t in u m . nm e nt s mt o b e sg in t h ein st h ifnta ls e tqrua en s cme . A s t h se sifht ifct le vp eo r MANUAL TRANSMISSI ON NV3500

DES CRI PTI ON

The transmissi on is a medi um-dut y  y 5-speed, constant mesh f  fu   ll y  y s y  ynchroni zed manual transmi ssi on wi th f  fi  f  ft  h gear overdrive range. The transmissi on is avail abl e i n two and f  fo   ur-wheel dri ve conf  fi  gurati ons. The transmissi on gear case consi sts of  f  two al uminum housi ngs (F i g. 1). The clutch housi ng is an i ntegral part of  f  the transmi ssi on f  fr  ont housi ng. A combi nati on of  f  rol ler and ball bearings are used to support the transmissi on shaf  ft  s in the two housings. The transmi ssi on gears all rotate on caged t y  ype needl e beari ngs. A roll er beari ng is used between the input and output shaf  ft  . The transmi ssi on has a si ngle shaf  ft  shi f  ft  mechanism with three shi f  ft  f  fo   rks al l mounted on the shaf  ft  . The shaf  ft  i s supported in the f  fr  ont and rear housi ngs b y  y bushi ngs and one li near ball beari ng. I nternal shi f  ft  components consi st of  f  the f  fo   rks, shaf  ft  , shi f  ft  l ever socket and detent components

splined to the transmission input shaf  ft  and is turned at engi ne speed at all ti mes that the clutch i s engaged. The input shaf  ft  is connected to the transmissi on countershaf  ft  through the mesh of  f  f  fo   urth speed gear on the input sha f  ft  and the f  fo   urth countershaf  ft  gear. At this poi nt, all the transmi ssi on gears are spinning. The driver sel ects a parti cular gear b y  y moving the shi f  ft  l ever t o the desired gear posi ti on. Thi s movement moves the i nternal transmissi on shi f  ft  components t o begi n the shif  ft  sequence. As the shi f  ft  lever moves the sel ected shi f  ft  rail, the shif  ft  f  fo   rk attached t o that rail begi ns to move. The f  fo   rk i s positi oned i n a groove i n the outer ci rcumf  fe   rence of  f  the s y  ynchroni zer sl eeve. As the shi f  ft  f  fo   rk moves the s y  ynchroni zer sl eeve, the s y  ynchronizer begi ns to speed-up or sl ow down the sel ected gear (depending on whether we are up-shi f  ft  ing or down-shi f  ft  ing). The s y  ynchroni zer does this b y  y havi ng the s y  ynchronizer hub spl ined t o the mai nshaf  ft  and movi ng the bl ocker ring into contact wi th the gear ’s f  fr  i cti on cone. As the bl ocker ri ng and fr  i cti on cone come together, the gear speed i s brought f  up or down to the speed of  f  the s y  ynchronizer. As the two speeds match, the spli nes on the inside of  f  the s y  ynchroni zer sl eeve become ali gned with the teeth on the bl ocker ri ng and the f  fr  i cti on cone and eventual l y  y wi ll sli de over the teeth, l ocki ng the gear t o the mai nshaf  ft  , or countershaf  ft  , through the s y  ynchroni zer.

htipnoaogAurstsu.ciopnTfmghotsebhr it(enFr taihgrniae.osnm1tsr)mi.oa fniTsisrhomineloinesgc leuifaoratronc nhdtsahhlb oa frultoss ibanietngae .rtioishnnegacsntawagiroenedtheutogysrepade-l tsanm liozgtverhveoass,vltetrhhaevinles.sbetAylhngseccitnteohsrduotnsose ihhrzmieffctrtoirvfrbcoeauer.igmklT,infteshroevtfnoscrshek itpfhotsef fdpots -hryuksnepicash oytrnoaenccsdhihlzroeeiowndibnTnyiehspTemudhb tsleuehwaatbinrfdtahnanigotssihumrtguapeispnu. dtiAsoohsrnrhifneatldffteo.isrlnr kbat hasaeilnifnrgbmglaenolitsus anhbu aesefadtdriosenbhnageir.tfwthIeonmutsnee cirnh hfgaats-l. tfduwmrhopiaiwtc-hsnnihobstinhyf taeicehnfotgagsneve aolinrrcd’ogstmemfotdrehwiocegvntei-agosyenhgnti(hfcctdtoheinrnrep,og tn.b)h.ilAdzoeTesc gkhr tegeeharorsunybbsinwplocseghcpkerlditeonhrniteseoidzrbicwrtgooneud gtaoanhhrcdeestt lscelhuvTitefhctr e scmo msaknpeeumot anable tydrtasfndr soecmto inssttihiocetn mornfep gco tnnhiveen. stfTsophro kw se,crlust hhcra ofu ,dg ihsscht hiifest ttsuwm hwypiaenlo cnbhrsslrphdoiecadnkfewidtz,seorvmtiesncarlgoetuchtavnhne,edsbtprhtshech oeadtmsfhfpore,lifictnalthleircosgok nuionsecydgohnntwcethhietraehonisndgty hsezn ieaecdvrrht. enAtoontsfu iaztt lohh rnyee. OPERATI ON

O P E R A T IO N

The manual transmissi on recei ves power through the clutch assembl y  y f  fr  om the engine. The clutch disc is

21 - 2

MANUAL TR ANSMI SSI ON - NV3500

2M1A -N2U A LM AT NRUAANL STMR AISN S MIOISN I-O NN V-3N5V03 5 0(C o n t in u e d )

MANUAL TRANSMISSI ON - NV3500 (Conti nued )

Fig. 1 NV3500 TRANSMISSION 

DR

DR

DR

MANUAL TRANSMISSION - NV3500

21 - 3

DDLMOIRAAWGN NLUUOABSLRI TC AR NA DN LST EMVSITLSIN IGO N - N V 3 5 0 (C o n t in u eIanldSsy)uefvtMeihcrAeNhUtni,gAthLmilaypTraRoiunApdeNirbSclaMeroItScrannoItfOsmNmaiis-nliauNotbneVrd3inc5laou0insbtericipsarno2gbt1elnw-emirl3-. Arsm eioasc ut ilntlohugwobfsrtuirciranlfnenag as,ctmk os,liersvon efiaorldton emc qhlue bgtcahkrtiaee.cralLfuncebtoarnlkieetcs/,vareneclatad rinfs plsgteoecoarnluesorr. an Alaeityxn scttuohhnsree-- flpdura bomkrmsiacogtae n.tdrpa rpboiedalre wimn eg,asc.a noT fha lgse ao vrl sea,r dhseyao tcinh egrao rsc,a uns h e fdb e arb aryin sag, REM OVAL MANUAL TRANSMISSI ON - NV3500 (Conti nued )

DIAGNOSIS AND TES TI NG L OW LUBRI CANT LEVEL

 y the A l ow transmi ssi on l ubri cant l evel i s general l y resul t of  f  a l eak, inadequate lubri cant f  fi  ll or an i ncorrect l ubri cant l evel check. L eaks can occur at the mating surf  fa   ces of  f  the gear case, adaptor or extensi on housi ng, or f  fr  om the f  fr  ont /rear seal s. A suspected leak could al so be the resul t of  f  an overf  fi  ll condi ti on. L eaks at the rear of  f  the extensi on or adapter housing wi ll be f  fr  om the housing oil seals. L eaks at component mating surf  fa   ces will probabl y  y be the resul t of  f  inadequate seal er, gaps i n the seal er, i ncorrect bolt ti ghteni ng or use of  f  a non-recommended seal er. A leak at the f  fr  ont of  f  the transmissi on wil l be f  fr  om either the f  fr  ont bearing retai ner or retainer seal. L ubri cant ma y  y be seen dri ppi ng f  fr  om the clutch housi ng af  ft  er extended operati on. I f  f  the l eak i s severe, it ma y  y also contami nate the cl utch disc causing the di sc to slip, grab and or chatter. A correct lubri cant l evel check can onl y  y be made when the vehi cle i s level. Also all ow the l ubri cant to settl e f  fo   r a minute or so bef  fo   re checking. These recommendati ons wil l ensure an accurate check and avoi d an underf  fi  ll or overf  fi  l l conditi on. Al wa y  ys check the l ubri cant l evel af  ft  er an y  y addi ti on of  f  f  fl  ui d to avoi d an i ncorrect lubri cant l evel condi ti on.

S evere hi ghl y  y audi ble transmi ssi on noise i s generall y  y the i ni tial i ndi cator of  f  a lubri cant probl em. I nsuf  ff  f  i  ci ent, improper or contami nated lubri cant will promote rapi d wear of  f  gears, s y  ynchros, shi f  ft  rai ls, fo f    rks and bearings. The overheati ng caused b y  y a l ubri cant probl em, can al so l ead to gear and bearing damage.

REMOVAL

picpnoeo gnLc teeweiandiktlosmlneba.aaetkt ifnrhcogeomusr luetdarhfreaa oclhsef ostuhwbseienl gxtpthoereinlbsrieoebsnaulyslot.rb Loa efdt haakepnstreaerostvhueclortufmiosl-f u p ((w123 ))a rSDRd heismfcntoo nvs reh aeinfcthts mlbfetaivstebrieorentyx ibn eentzgos ailoNtnisv.cue tecrwa bs .lea .n d s lid e b o t iteLniugtaAhhbdetleirqcnaauiktnh gaeet omfsrrheaoueayn lstfer ,bonefgtasaroepifnn toghin-drrette hcpaoeinm ssneergaislnoefrdri,oe mnrdien wtscaeoihanleeb rrc.ctlfsurbetoacmlhlt. t o w((( 4567e)))r RRDa eern ammidsienoolv veleu hsbrskirhcailidcsfat pneo lmnla tvbiheflo,yrit.srftae.exn qtseum ipssioeindo n. frwo mil tb he e d isshaisfthiswneohgvA eestnrchnoet,grhidte asmvtfcteaehltyuroicbalreelxsicpoitase,ncnlgtoedrvltedbav.me oAlipncdeshor oeaerat kilocho ewa. tcntlIehufroe.ncthluyed brisielcce aamnk taudieos- fsrleeamm((n89 gob)) veleDM diapysfocrokornpe s/pyleercokvtrpe selh. arfnrote/sshhianafrftots/ma.s lh ac lfitipos sn ao nnr ed ft r racenonms cmep iasn iioo nnd stoaa hmvn teo iilldnuecnbaof ord irceutaaino dtmn esulrnbfvwureitilcloa nroftereonlrvs eouav renfbilyel fcaaocrdnnoe idcathitoe nuco kn.r ai.fntAeg l.uwciTdahytescosk ahvareoencickdd- rh eo m((u11 so02iv))n egRR.teer mma noo svvfee rt rscala nsvse feifr ceycqal usneidp liren dkm.maogoueun nitftniengqgu inpnu utestd . aa nn dd r e m o v e c y l i n d e r ( F i g . 2 ) . HlisneoAvgqieRs.ualeD,S,rndiumcSbexsHpschtrIiaFosffntTpiiteInvuNragesGloiinwrsguecubaosrnu,otcanailm-nrtyeincclonaemtau lksesbdelinucbadynreidacarnenldlsoutuwbshl.rtilTcuiadhnbnertigcsheaoafnitrst--, sicgnaho gtSeifishota iunfrstnda doiclnefo,tm isoscpymetoe.npcd eho fnnr ote ,ndtaa ndm eda axmgtbeae ngaodrreiand drgpa emdur aisomugdeaa,dlgtyhc.elu Iatifcr dhsat pihlnr edfstik-siioWsnur cordrae ni apvcoslera dtadcenaes dmhc,riaafutdgsieesdafcriosnycrtno.lecar Ws erhdoco tr rdnitiu/nedrlganisnm gsclaagp.nserhIdofcibactpaulsrbu etesc agh une arpa eu rsoecpbslaua ltmothef. rTscw atRhibscAeeuk NilStstshhMigrisfaIhtSctinlosyngmIOdciNisnat utioosnnOa swIg,SyinElhfea rewdcs alyiornnrdce hngareoistry.hi eIsgnhr isfnotgsma. y Iw ntne eamwrd-oiotns r. iswnphgMe i nodesstr.t hm a atl noiusp ae lruatdr iaobnlse.m,R biosut aiognesng m r eaa lk rey sogoemlny e r an to eisxaet rmde uilrde-

(1) Disconnect batter y  y negative cabl e. (2) S hif  ft  transmi ssi on into Neutral. (3) Remove shif  ft  boot bezel screws and sli de boot upward on shi f  ft  l ever extensi on. (4) Remove shi f  ft  l ever extensi on f  fr  om the shi f  ft  t ower and l ever assembl y  y. (5) Rai se vehi cl e on hoi st. (6) Remove ski d plate, i f  f  equi pped. (7) Drai n l ubri cant i f  f  transmissi on will be di sassembl ed f  fo   r servi ce. ft  /shaf  ft  s and compani on (8) Mark propeller shaf  fl  ange yoke/ f   yokes f   y fo   r instal lati on ref  fe   rence and remove propell er shaf  ft  /shaf  ft  s. (9) Disconnect harness f  fr  om cl ips on transmi ssi on housing. (10) Remove transf  fe   r case linkage i f  f  equi pped. (11) R emove transf  fe   r case mounting nuts and remove transf  fe   r case i f  f  equi pped. (12) Remove slave c y  yli nder mounting nut and remove c y  ylinder (F i g. 2).

HARD SHIFTI NG

Hard shif  ft  ing is usuall y  y caused b y  y a l ow l ubri cant l evel, i mproper or contami nated lubri cants. The consequence of  f  usi ng non-recommended lubri cants is noi se, excessive wear, internal bind and hard shi f  ft  ing. S ubstantial l ubri cant l eaks can result i n gear, shi f  ft  rai l, s y  ynchro, and beari ng damage. I f  f  a l eak goes undetected f  fo   r an extended peri od, the f  fi  rst i ndi cati ons of  f  component damage are usual l y  y hard shi f  ft  ing and noi se. S hif  ft  component damage or damaged cl utch pressure plate or disc are additi onal probable causes of  f  increased shi f  ft  ef  ff  f  o   rt. Worn /damaged pressure plate or disc can cause i ncorrect release. I f  f  cl utch probl em is advanced, gear clash during shi f  ft  s can resul t. Worn or damaged s y  ynchro rings can cause gear clash when shi f  ft  ing i nto an y  y f  fo   rward gear. I n some new or rebuil t transmissi ons, new s y  ynchro ri ngs ma y  y tend to sti ck sli ghtl y  y causing hard or nois y  y shi f  ft  s. I n most cases thi s conditi on will decli ne as the rings wear-i n.

TRANSMISSION NOISE

Most manual transmi ssi ons make some noi se during normal operati on. R otating gears generate a mild whine that is audi ble, but generall y  y onl y  y at extreme speeds.

Fig. 2 SLAVE CYLINDER 

1 - MOUNTING NUTS 2 - SLAVE CYLINDER

21 - 4

DR

MANUAL TR ANSMI SSI ON - NV3500

2dMu1(As1-tN3 4)sUhRiAelmLdM oaATvnNeRdUAsAtuNaLsrSptTeMRrn AIsmSiN onStMIcOr,IoSNstrIm-OueNcNmtVub-r3eaN5lV0(dF3u5igs0t.(C3c)oo.vne rt,in u ee nd((g12)i90n))e .RM eomv eo vtera nb oslmtsis aito na crheianrgw atrrad nusnm tiisl iinopn u ttoshDtahRfet jDFiasRI SckOlAeNa Tnr SdHEfrOMecUmlBuSoLIcvYNhe G dt r a cn sam dis pio n s fur o me p ulan de . rT vh e n icloe w. e r (lsuiob(n123r ))icdaIISufnhrstili.pfuntebgc trircadenmrsatmoivniws pla,ilsournge moimn tavdogernNaedietnruaftodirnra old.pueltb rgoifs a. tnr da n ds mr a isnMANUAL TRANSMISSI ON - NV3500 (Conti nued )

(13) R emove starter motor, structural dust cover, dust shi el d and suspensi on crossmember (F i g. 3).

(19) Remove bol ts attachi ng transmi ssi on t o the engi ne. (20) Move transmi ssi on rearward until input shaf  ft  i s cl ear of  f  clutch di sc and pressure plate. Then l ower  j jack and remove transmi ssi on f  fr  om under vehi cle.

DIS ASSEMBLY

FR ONT HOUSI NG

(1) S hif  ft  transmi ssi on into Neutral. (2) I f  f  lubri cant was not drained out of  f  transmissi on duri ng removal, remove drain plug and drai n l ubri cant. (3) I nspect drain plug magnet f  fo   r debri s. (4) Remove backup li ght swi tch l ocated on passenger side of  f  rear housi ng (F i g. 5).

Fig. 3 DUST COVER 

(g e r4 )s idR e m fo vr e a br a hc ok u sp nlig h(Ft isg w. i5t)c.h lo c a t e d o n p a s e n -

1 - DUST SHIELD 2 - STARTER MOTOR 3 - DUST COVER 4 - CROSSMEMBER

(14) R emove exhaust pipe f  fr  om the exhaust mani fo f    l ds. (15) S upport engi ne wi th ad j justabl e jack stand and wood bl ock. (16) S upport and secure transmi ssi on to a transmi ssi on jack with saf  fe   t y  y chai ns. (17) R emove bol ts f  fr  om the rear transmi ssi on mount. (18) R emove the rear crossmember and transmissi on mount (F i g. 4).

(faonl((dd111 s456w.))) o SSR duue mppb oloovrrcettk .aexnnhdga iuns seetc upwrieiteht rfaraondmsjmu stihtsae biolenx h tjaoauc ska t tmsrtaaannn sid-msm ioio((sn11u 78nim))ot n.oRRujeeanmmct koo(vvFweeigi t.hbh 4oes)l.tarfe atfryr occmrh oasi tmh .ee m rbeearr a nt rda nt rs am n iss m iiosn- le v( 5e r) aR se m o vbelys h( Fif tg . o 6w ) .e r b o lt s a n d r e m o v e t o w e r a n d Fig. 5 BACKUP LIGHT SWITCH 

1 - BACKUP LIGHT SWITCH

(5) Remove shi f  ft  tower bol ts and remove tower and l ever assembl y  y (F i g. 6).

Fig. 6 SHIFT TOWER  Fig. 4 CROSSMEMBER  1 - TRANSMISSION MOUNT 2 - CROSSMEMBER

1 - SHIFT TOWER 2 - SHIFT SOCKET 3 - SEAL

DR

MANUAL TRANSMISSION - NV3500

21 - 5

DtbMoupR(As6hN)oifnRUgreAmanLotdvTheloResuvhAeirNfntgS.sMhTaIfSet bloIclOkt Nsbeoc-lut rN(eFVs ig3th.5e70)s hfrio(tCm so tnahftetin u e9 )d.(8) ) MR Ae mN oUvAeL b eTaRrAinNgS rMe tIaS inIeOrNfro-mN Vin3p5u0t sh a f2t 1(F-ig5. MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(6) R emove shi f  ft  shaf  ft  l ock bolt (F i g. 7) f  fr  om the top of  f  f  fr  ont housi ng. The bolt secures the shi f  ft  shaf  ft  bushing and l ever.

(8) Remove bearing retainer f  fr  om i nput shaf  ft  (F i g. 9).

NOTE: This is a special bolt and can not be substituted with any other bolt.

Fig. 9 INPUT SHAFT BEARING RETAINER  1 - SHAFT BEARING 2 - BEARING RETAINER 3 - INPUT SHAFT

Fig. 7 SHAFT LOCK BOLT 

ft  snap ri ng (F i g. 10). (9) Remove i nput shaf 

( 9 ) R e m o v e i n p u t s h a f t s n a p r i n g ( F i g . 1 0 ) . t oh (eb7 )fre oRa nketm sheo av ulees rin bpg e,uatd sehlona fsctea br(eFfauirgli.ny g8 )p.r eyt aoin e trh be o rltes afirno em r 1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET

(7) R emove i nput shaf  ft  beari ng retainer bolts f  fr  om the f  fr  ont housing, then caref  fu   ll y  y pr y  y on the retai ner to break seal er bead l oose (F i g. 8).

Fig. 10 INPUT SHAFT SNAP RING  1 - INPUT SHAFT SNAP RING 2 - OIL FEED

Fig. 8 BEARING RETAINER SEAL 1 - PRY TOOL 2 - INPUT SHAFT BEARING RETAINER

21 - 6

DR

MANUAL TR ANSMI SSI ON - NV3500

2ogMfe1(rAt1s-hN0eo6)UftRrAahe nmLeMsormATveNeiRUAsAvhoNeiLnfrtSwTMsoRihtAIaShNftReSddMImeOetItoSNvnnettIr-Opp8NNll1uuVgg-73AfNa5rn.oV0dmA3 5pt0auh(csCehosftinhdntee-in u efhrado(mn1) t3 ) heSro.eupsainrag teo fth ea lhigo nu msine g st (dF oigw.e1ls2 ) wb yi hta p ipn lgaDsthRiec MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(10) R emove shi f  ft  shaf  ft  detent plug f  fr  om the si de of  f  the transmissi on with Remover 8117A. Attach f  fi  ngers of  f  the remover to the detent plug and push the cup down ti ll it contacts the trans. Then ti ghten the nut ti ll i t pull s the pl ug f  fr  om the case. (11) R emove shif  ft  shaf  ft  detent plunger and spri ng wi th a pencil magnet. (12) R emove bol ts that attach f  fr  ont housi ng to the rear housi ng (F i g. 11). Three bol ts at extreme rear of  f  housi ng are f  fo   r the output shaf  ft  beari ng retai ner. L eave one bol t i n place until geartrai n i s read y  y to be removed f  fr  om case.

(13) S eparate the housi ngs (F i g. 12) b y  y tappi ng the ff r  ont housi ng of  ff  f    ali gnment dowel s wi th a plasti c hammer.

cnw ui((ptt11h 2d)i)aol wRRpinee mnmptcioouilvlv eemist bacohgoilenftntsetpastl.chhu taags ttftrahdoteme attcrnhahtnefsrp .colaunTsnth ghe.enoru tsaiignnhdgt estnpo r ttinhh gee rrhL eoeamuarsvo iehn ogodun seafirrnbegmo l(ftFocriiangs.teph1.lea )c.oe Tu th pnrue itl bgs eoh latrfst aabineax tsirnergme a ed yrte aionr eborf.

Fig. 12 FRONT HOUSING  1 - FRONT HOUSING 2 - REAR HOUSING 3 - DOWELS (2) 4 - PLASTIC MALLET

(14) Remove input shaf  ft  beari ng and countershaf  ft  fr  ont beari ng race (F ig. 13). f 

(fr o n1 t4 )b R aermin ogv er a icnep u( Ft igs .h a1 f3t) .b e a r in g a n d c o u n t e r s h a ft Fig. 11 HOUSING & BEARING RETAINER BOLT  1 - RETAINER BOLTS 2 - HOUSING BOLTS 3 - RETAINER BOLT 4 - HOUSING BOLT LOCATIONS

Fig. 13 Input Shaft Bearing and Countershaft Front  Bearing Race  1 - INPUT SHAFT BEARING 2 - FRONT HOUSING 3 - COUNTERSHAFT FRONT BEARING

DR

MANUAL TRANSMISSION - NV3500

21 - 7

DaMnR(Ad1 N5g)eUaNAroLtae iTnp oRcsAitmNopnS Moef IiStnsp uiIntO sNho ua-fsti,Nn gsVh(i3Fft5gs0.h 1a4ft(),.C foo rnktsin u e d ) M A N U A L T R A N S M IS IO N - N V 3 5 0 2 1 - 7 MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(15) N ote posi ti on of  f  i nput shaf  ft  , shif  ft  shaf  ft  , f  fo   rks and geartrai n components in housing (F i g. 14).

Fig. 15 DETENT SPRING AND BALL 1 - SHAFT LEVER 2 - SPRING AND BALL 3 - MAGNET

Fig. 14 GEARTRAIN AND SHIFT COMPONENT  1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER AND SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT 7 - 1-2 FORK 8 - INPUT SHAFT 9 - 3-4 FORK

SHIFT/FOR K SHAFTS AND REVERSE IDLER SEGMENT

StsahEHi((iGn12fItF))MtTfhPR/EFerloNakOtTcsaRevKeanrSldsdHhvceoAatprtFcnTthaoSnwbbdAaae NllbDouaavsnneRhddriEntVssghpp errRuiinnsSphggwE.a(afIFtrDidlgLe.Evo1Reu5rt).toof ctohne(3 ) U n e a t s h if s o c k e t r o l p in w th R e m o v e r 6 8 5 8 .

(1) Pl ace a shop towel over the shaf  ft  l ever to contai n the l ever detent ball and spring. (2) R otate lever and bushi ng upward out of  f  the shi f  ft  f  fo   rks and catch bal l and spring (F ig. 15). ft  socket roll pin with Remover 6858. (3) U nseat shif  Positi on remover on shif  ft  shaf  ft  and center tool over the roll pi n. Veri f  f y  y   tool l egs are f  fi  rml y  y seated on the shi f  ft  socket (F i g. 16). f  the case to avoi d (4) Til t socket toward the si de of  trappi ng the pin between the gear teeth. (5) Ti ghten remover t o press the roll pi n downward and out of  f  the shi f  ft  socket (F i g. 16).

Ptts rhoa(eis4fpit)rt soTlnonigclpkrtieenhstmo.e c(oVFkpveiegntri.fby1ooe6nwtt)oa.srehld ifnett hg se h sa irfgdet e aaf iornrfmd t lhcyeet nhsc.taeasr ee tdto o lna ov tvoheidr w a(r5 d) aT ni d o unt orfe mt hoev s rh ift o s po rc ke s (tFh ieg . r1o 6l ). p in d o w n (a h6a)m D r iv e a on ud t psuh nifcth b (uFs hg i.n 1g 7 a).n d le v e r o l p in w it h

Fig. 16 SHIFT SOCKET  1 - REMOVER 2 - SHIFT SOCKET

NOTE: Roll pin mus NOTE: mustt onl only y cle clear ar the shift shaft. shaft. Do not push the pin into the geartrain.

(6) Drive out shi f  ft  bushi ng and l ever roll pi n wi th a hammer and punch (F i g. 17). NOTE: Use proper size punch to avoid bending the shift shaft.

Fig. 17 SHIFT SHAFT LEVER & BUSHING ROLL PIN  1 - PIN PUNCH 2 - BUSHING AND LEVER 3 - SHIFT SHAFT

21 - 8

DR

MANUAL TR ANSMI SSI ON - NV3500

2sMh1(Ai7f-tN) 8sPUoucAkl eLMts,AhT iNRftUAAs-NrhLeaSvfTetMRr sAIetSNrfaSoiMIrgOkhItSNa noIdu-OtN1N -oV2f-3rNo5eVak03r (5Fh0i(ogCu.so1inn8g)t.,in u eftohdr(ek1)n0c)rleRma orotsvae eh3if-3t4-4aforfmokrsk(Fo niagr.1o-u21n )da.n sdy nficht r-o esvlersv e fouDrnktRsil, MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(7) Pull shi f  ft  shaf  ft  strai ght out of  f  rear housi ng, shi f  ft  socket, f  fi  f  ft  h-reverse f  fo   rk and 1-2 f  fo   rk (F i g. 18).

(10) Rotate 3-4 f  fo   rk around s y  ynchro sl eeve until ff o   rk cl ears shi f  ft  arms on 1-2 and f  fi  f  ft  h-reverse f  fo   rks, then remove 3-4 f  fo   rk (F i g. 21).

Fig. 18 SHIFT SHAFT  1 - SHIFT SHAFT 2 - 3-4 FORK 3 - SHAFT DETENT NOTCHES

(8) R emove shi f  ft  socket f  fr  om rear housi ng (F i g. 19).

Fig. 21 3-4 SHIFT FORK  1 - 3-4 FORK 2 - 1-2 AND 5TH-REVERSE FORK ARMS 3 - 3-4 SYNCHRO SLEEVE

(8 ) R e m o v e s h if t s o c k e t fr o m r e a r h o u s in g (F ig . 1 9 ) . lo (s1 e n) Rr eamr o v e r es v e rids le ridslhe ar f ts hb ao flt (sFu ipg . o2r t ).b o lt a n d

(11) R emove reverse i dl er shaf  ft  support bolt and l oosen rear reverse i dl er shaf  ft  bol t (F i g. 22).

Fig. 19 SHIFT SOCKET & ROLL PIN  1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET

(9) R emove shaf  ft  l ever and bushi ng (F i g. 20).

(9 ) R e m o v e s h a ft le v e r a n d b u s h in g (F ig . 2 0 ).

Fig. 22 REVERSE IDLER SHAFT & SUPPORT  1 - SUPPORT BOLT 2 - SHAFT BOLT

Fig. 20 SHIFT SHAFT LEVER & BUSHING  1 - SHAFT LEVER AND BUSHING 2 - 3-4 FORK

DR

MANUAL TRANSMISSION - NV3500

21 - 9

DbMyR((A11sN23li))dUSRnAuegmLpitooTvsreRt AareieNgvaheSrtrsMoeauIintSidolafeInrhOdosNuhraei-afntrgN.shVuop3u 5soi0rntg soe(nCg moFeninxtt-in u e d ) M A N U A L T R A N S M IS IO N - N V 3 5 0 2 1 - 9 MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(12) R emove reverse i dler shaf  ft  support segment b y  y sli di ng i t strai ght out of  f  housi ng. (13) S upport geartrai n and rear housing on F ixture 6747 as f  fo   ll ows: (a) Ad j just hei ght of  f  reverse i dler pedestal rod until the reverse i dle shaf  ft  bottoms i n Cup 8115. (b) Posi ti on Adapters 6747- 1A and 6747-2A on F i xture 6747. (c) S li de f  fi  xture t ool ont o i nput shaf  ft  , countershaf  ft  and i dl er gear (F i g. 23). (d) S tand geartrain and rear housing upri ght on fi  xture (F ig. 24). Have hel per hold f  f  fi  xture tool i n place whil e housing and geartrai n i s bei ng rotated i nto upri ght positi on.

t u ruF enix((tab6ti))ul7 4rtPAe7h ode6sajui7srt4e fotv7on.lhr oseAwigsah:dptlte o rsf h rae6fvt7 e4br7os-te1 Ao imd lase ridn p 6Ce 7du 4eps7 t-8a21lA 5r oo. nd (fspihlxa(atcdcuf))tr eSaSw lnthi(adF nleie d.fhligex2ort4uau)sg.ritenHagrtaionv(Fnelaidgnho.dgne 2ltrpao3er)a.tirn aphiunoltud isssifhnbxagetfitun,pge cr iortguohnatltteoeirndin to u p r ig h t p t o .

Fig. 24 GEARTRAIN & HOUSING ON FIXTURE  1 - INPUT SHAFT 2 - COUNTERSHAFT 3 - FIXTURE 6747

Fig. 23 FIXTURE ASSEMBLY  1 - FIXTURE 6747 2 - ADAPTER 6747-1A 3 - CUP ADAPTER 8115 4 - REVERSE IDLER PEDESTAL 5 - ADAPTER 6747-2A

(14) R emove rear bol t holdi ng reverse i dl er shaf  ft  in housi ng.

iRbnoE((lA11ht s)4oR )u tsHhRinnOae tgmU2. -SoawvItNheaeGcrhel-a d2ro ruWibtvopDelut t hr aso hnldas imfnt gisb reieao vnr ei, r sgr ee mriedotlvaeeirn etshh raetfot irne ga .r c a s e (F ig . 2 5 ). B l s a r e r e r o f s h f t o w e r o p e n REAR HOUSING - 2WD

(1) On 2-wheel dri ve transmi ssi on, remove three bol ts that attach output shaf  ft  beari ng retai ner to rear case (F i g. 25). B ol ts are rear of  f  shi f  ft  t ower opening.

Fig. 25 OUTPUT SHAFT  1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT IS AT OPPOSITE SIDE OF CASE)

21 - 10

DR

MANUAL TR ANS MISSI ON - NV3500

DR

2bMe1(Aa2-rN)in1TUg0aApw LirtMheTaArRNhpAUloNaAu sLStinMcT/grRIaSuA pNhwSIiadOMreNdISh a-nmIONd NVoef3r- 5(oNFu0Vitgp3.u52(t0C6 s)o.h na fttin u e d )

MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(2) Tap rear housi ng upward and of  ff  f    output shaf  ft  beari ng wi th a pl asti c/rawhi de hammer (F i g. 26).

Fig. 27 REAR HOUSING - 2WD  1 - REAR HOUSING 2 - SHIFT FORKS AND GEARTRAIN

Fig. 26 SEPARATE REAR HOUSING & OUTPUT  SHAFT BEARING  1 - REAR HOUSING 2 - MALLET 3 - FIXTURE

(3) L i f  ft  rear housi ng up and of  ff  f    geartrai n (F i g. 27). (4) R emove countershaf  ft  rear beari ng f  fr  om countershaf  ft  (F i g. 28).

(t e r s34 h) a LRf tiefmt(F roievg a. r2ch8 o).unstien rgs hu ap fta nr ed a or f b g e a rint ga ifnr o(mF ig c.o 2u 7n)-.

Fig. 28 COUNTERSHAFT REAR BEARING  1 - COUNTERSHAFT REAR BEARING 2 - OUTPUT SHAFT 3 - COUNTER SHAFT

DR

MANUAL TRANSMISSI ON - NV3500

21 - 11

DRiMnEtR(AoA1 N)R IUAn AsDeoLrfPtiTTnhEgRe RAdsicHNmrOeSpwUlMeSsfIIrNSionGm fI-aOsc4leNiWdoeDf- hrNeaVmr3 s5e0ar l (F(iCg .o 23n90t)in u eshd(a2)f)Mt (RAFeNimgU.oA3vL1e ).TrRe aArN Sb Me aIrSin gIO sNn a-p N Vri3n 5g 0 fro m 2 o1u -tp1u t a d r e m v e s a l. MANUAL TRANSMISSI ON - NV3500 (Conti nued )

REAR ADAPTER HOUSI NG - 4WD

(1) I nserti ng screw f  fr  om sli de hammer (F i g. 29) into one of  f  the dimples i n f  fa   ce of  f  rear seal (F i g. 30) and remove seal.

(2) Remove rear bearing snap ri ng f  fr  om output shaf  ft  (F i g. 31).

Fig. 31 REAR BEARING SNAP RING  Fig. 29 REAR SEAL 1 - SLIDE HAMMER 2 - REMOVER TOOL 3 - REAR SEAL

1 - HEAVY DUTY SNAP RING PLIERS 2 - REAR BEARING SNAP RING 3 - OUTPUT SHAFT

ft  rear adapter housing upward and of  ff  f    (3) Li f  geartrai n (F i g. 32).

(g e a3r)t La inft ( Fr iega.r 3 2a)d. a p t e r h o u s in g u p w a r d a n d o f Fig. 32 REAR ADAPTER HOUSING  1 - REAR ADAPTER HOUSING 2 - OUTPUT SHAFT

Fig. 30 REAR SEAL FACE  1 - DIMPLES 2 - SEAL FACE

21 - 12

DR

MANUAL TR ANS MISSI ON - NV3500

2tbMe1p(Aa4-rN)bin1eRUg2a eArimnLotgavMTioenAuRbNtreAUoaNfrAihLnSdogMuTrsRIeiSAntragNibnSIwOeMartNIhibSnoag-ltIOsNh(FaNaVimng3-.d 53Nre0erV)m.3ho5Pa(v0unCesdohrleenaoitrfin u eo nd((12)o))u tPRpoeusmti osvohena fstBn.eaaprirning gStphlaitt esre c1u r3e0s 3b-e4twsyen nch sroe cDho nuRdb MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(4) R emove bearing retai ner bolts and remove rear beari ng retai ner and rear bearing (F ig. 33). Push or tap beari ng out of  f  housing with a hammer handl e if  f  needed.

ne ded.

NOTE: Hou NOTE: Housin sing g mus mustt be rep replac laced ed if rac race, e, bea bearin ring g bore or idler shaft notch are worn or damaged.

(1) Remove snap ri ng that secures 3-4 s y  ynchro hub on output shaf  ft  . (2) Posi ti on B eari ng S pli tter 1130 between second and thi rd gears and press of  ff  f    3-4 s y  ynchro assembl y  y, third gear s y  ynchro ring and third gear with a shop press. (3) Remove third gear needl e beari ng (F i g. 34).

tap hn i(edr3s )t.hRg ieeradm ogsveyeanrtcshh iarrond drgiepn arg re san ne do fd tlhe3i-rb4de asgryeinna cgh r(wFo iitgah.s 3ae4m)s.hb olyp, Fig. 34 THIRD GEAR NEEDLE BEARING  1 - THIRD GEAR NEEDLE BEARING

(4) Remove retai ni ng ring that secures two-pi ece thrust washer on shaf  ft  wi th a small pr y  y tool (F i g. 35). Fig. 33 REAR ADAPTER HOUSING COMPONENTS 

(t3 h5 r)4.u )s tR we ma so hv e r oe nt a isnh a fgt rw in tgh t h astm saelc u pr e ys t w ol-p( Fie cg .

1 - BEARING RETAINER 2 - RETAINER BOLTS (3) 3 - IDLER SHAFT NOTCH 4 - COUNTERSHAFT REAR BEARING RACE 5 - REAR BEARING

GEARTR AI N FR OM FIXTURE

GcahsE(((rA123eo)))mRsTSRbl leeiymmdAv fIeooiNsxvvc.teeoFuuR1nrO-te2eMcvrueasprhnFs.aIdeXftTfiiUodutRlhteE-rroefvgeiexrastreu refaosrtokesml.fbrloym fsryonm 4irnef tpa(5ru )ts buLRsorhielffamtascto .avnreoedf roieufmt hpougv te ead sr) .ho(aur eft tp au ibtne as rh wan figtl dar en odap inog ee rat or sfgreooamfr (Of o Uu 6rT )tPh UL giTfe aS rHnsAdyFnrTcehmr o vre ign pfur ot m s hta fet , f pxilou tr b. e a r in g a n d

 y f  fr  om (1) R emove reverse i dl er gear assembl y assembl y  y f  fi  xture cup. (2) R emove 1-2 and f  fi  f  ft  h-reverse f  fo   rks f  fr  om s y  ynchro sl eeves. ft  out of  f  f  fi  xture tool. (3) S l ide countershaf  (4) R emove output shaf  ft  beari ng retainer f  fr  om rear surf  fa   ce of  f  f  fi  f  ft  h gear (retai ner will drop onto gear af  ft  er bol ts are removed). (5) L i f  ft  and remove output shaf  ft  and gears of  ff  f    input shaf  ft  . (6) L i f  ft  and remove input shaf  ft  , pil ot bearing and fo f    urth gear s y  ynchro ring f  fr  om the f  fi  xture.

OUTPUT SHAFT

NOTE: Synchronizer hubs and sleeves are different and must not be mixed. Remove each synchronizer  unit un it as an as asse semb mbly ly to av avoi oid d mi mixi xing ng pa part rts. s. Ma Mark rk each synchro hub and sleeve with a scriber or paint for correct assembly reference.

Fig. 35 THRUST WASHER  1 - PRY TOOL 2 - THRUST WASHER RETAINING RING

DR

MANUAL TRANSMISSI ON - NV3500

21 - 13

DfnMorR(At5eiN)npRUotsaeAimltLao vniTe onRtfwAreoNfa-psSrhieeMncrcIelSo.thcarItuOisntNg wlu-agsNh Veinr3 (s5Fh0iagf.t 3n(6Co)tocahnnetdsin u e d ) M A N U A L T R A N S M IS IO N - N V 3 5 0 2 1 - 1 3 MANUAL TRANSMISSI ON - NV3500 (Conti nued )

(5) R emove two-pi ece thrust washer (F i g. 36) and note posi ti on of  f  washer l ocati ng lugs in shaf  ft  notches fo f    r i nstallati on ref  fe   rence.

Fig. 38 SECOND GEAR SYNCHRO RING & CONES 

Fig. 36 TWO-PIECE THRUST WASHER  1 - SECOND GEAR 2 - THRUST WASHER (2-PIECE) 3 - WASHER LOCATING LUG

1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - INTERM RING 3 - SYNCHRO FRICTION CONE 4 - SYNCHRO CONE 5 - SYNCHRO RING

(6) R emove second gear and needl e bearing (F i g. 37).

(3 7 6. ) R e m o v e s e c o n d g e a r a n d n e d le b e a r in g (F ig .

Fig. 39 HUB SLEEVE & 1-2 SYNCHRO  1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - BEARING SPLITTER 1130

Fig. 37 SECOND GEAR  1 - SECOND GEAR 2 - SECOND GEAR NEEDLE BEARING

 ynchro ring, s y  ynchro f  fr  i c(7) R emove second gear s y ti on cone, s y  ynchro cone and i nterm ri ng (F i g. 38). (8) R emove 1-2 s y  ynchro hub snap ri ng. (9) Positi on B eari ng S pl itter 1130 between f  fi  rst and reverse gear. Press of  ff  f    1-2 s y  ynchro hub, sl eeve and f  fi  rst gear f  fr  om output shaf  ft  with shop press (F i g. 39). (10) R emove f  fi  rst gear needl e beari ng (F i g. 40).

(ta ino(dn789 )) cr oePRR nvoeeesmmr,itoosevvy eenng ces1haBe-r2rce.oasnPcrydionnegcgshe arSoronpfdhsliyuti1nbe-ct2rhse nrso1may pnr3ic0nrhignr,bog es.(tyhFwnuigceb .h, nr3so8le)ff.irrivscet3 9 ()1. 0f i) sRt egm ao vr ef foimr s to gu et pa ur tn seh ad flte wb ieta r isn g p(F irg e. 4 0 ()F. ig .

Fig. 40 FIRST GEAR NEEDLE BEARING  1 - FIRST GEAR NEEDLE BEARING

21 - 14

DR

MANUAL TR ANS MISSI ON - NV3500

2M1(A1-N)1U4RAe mL oMvTeARNoAuUtNAp uLStMTshRIaSAftN bSIeOMaNrIiSn -g IONsnNVa p3- r5Nin0Vg 3 5F(0iCg .o4n1 t).in u e(Fd(ig1).5 )4 R).e m o v e fi th -re v e rse sy n ch ro h u b sn a p rDinRg MANUAL TRANSMISSI ON - NV3500 (Conti nued ) (11) R emove output shaf  ft  bearing sna p ri ng (F i g. 41).

(15) Remove f  fi  f  ft  h-reverse s y  ynchro hub snap ring (F i g. 44).

Fig. 41 OUTPUT SHAFT BEARING SNAP RING  1 - OUTPUT SHAFT BEARING 2 - BEARING SNAP RING 3 - SNAP RING PLIERS

ft  (12) On 2-wheel dri ve models, remove output shaf  beari ng. (13) R emove f  fi  f  ft  h gear (F i g. 42).

Fig. 44 FIFTH-REVERSE SYNCHRO HUB SNAP  RING  1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 2 - SYNCHRO HUB SNAP RING 3 - SNAP RING PLIERS

b e ((a11r23in)) g OR. en m 2 o-vw eh ef i lt hd rgiev ae r m (Fo dige .ls4, 2r)e. m o v e o u t p u t s h a f t w i(t1h 6 )s h Ro ep m p orv es fi(Ft hig-.r e4v5e)r.s e s y n c h r o h u b a n d s le v e

(16) Remove f  fi  f  ft  h-reverse s y  ynchro hub and sl eeve wi th shop press (F i g. 45).

Fig. 42 FIFTH GEAR  1 - FIFTH GEAR AND SYNCHRO RING

(14) Remove f  fi  f  ft  h gear needle bearing. S pread bearing  j just enough to clear shoulder on output shaf  ft  (F i g. 43).

(ju s t1 4e )n oRu eg mh otv e cflie at hr sg he ao ur lnd e r d olne bo eu at rp iun tg .s hS ap frte a(Fd igb .e a4 r3 i)n. g

Fig. 45 FIFTH-REVERSE SYNCHRO 

Fig. 43 FIFTH GEAR NEEDLE BEARING  1 - FIFTH GEAR NEEDLE BEARING

1 - PRESS 2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 3 - REVERSE GEAR 4 - OUTPUT SHAFT