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21 - 97
Fig.27FIXTURE/OUTPUTSHAFT
1 - OUTPUT SHAFT 2 - FIXTURE
Fig.28RemoveHoldingTool
1 - HOLDING TOOL 2 - 5-6 SYNCHRO
(3) Attach an engine crane or equivalent to Fixture 8232 and raise the geartrain approximately 1/4 in. from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
ing.
(5) Lower the geartrain back into the clutch hous-
(6) Install Holding Tool 8242 (Fig. 28) onto the 5-6
synchro and tighten the screw to hold the 5-6 syn- chro together during the removal operation.NOTE: Note the order of the shift fork arms at the primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
rails
from the rest of
the
(8) Remove shift geartrain (Fig. 29).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig.29SHIFTRAILS
1 - 5-6 SHIFT RAIL
21 - 98 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(10) Remove geartrain from the clutch housing and install the geartrain into Support Stand 8246 (Fig. 30).
DR
Fig.31FRONTCOUNTERSHAFTBEARING
1 - PULLER 2 - JAWS
Fig.30GEARTRAINFIXTURE
1 - FIXTURE 2 - SUPPORT STAND
(11) Remove Fixture 8232 from the output shaft
and the countershaft.
(12) Separate the countershaft from the output
shaft.
(13) Separate the output shaft from the input shaft. Hold the 5-6 synchro together while removing the output shaft to prevent the synchro sleeve from being dislodged from the synchro hub.
COUNTERSHAFT BEARINGS
(1) Remove snap-ring holding the front counter-
shaft bearing onto the countershaft.
(2) Remove front countershaft bearing with Collar 6444-8, Jaws 6451, Puller Rods 6444-4 and Puller 6444 (Fig. 31).
(3) Remove rear countershaft bearing with Collar 6444-8, Jaws 6447, Puller Rods 6444-4, Puller 6444
and suitable press button (Fig. 32).Fig.32REARCOUNTERSHAFTBEARING
1 - PULLER 2 - JAWS
DR MANUAL TRANSMISSION - NV5600 (Continued)
OUTPUT SHAFT BEARINGS
MANUAL TRANSMISSION - NV5600
21 - 99
(1) Remove snap-ring holding the pocket bearing
onto the output shaft.
(2) Remove pocket bearing from the output shaft with Sleeve 6444-8, Jaws 8234, Puller Rods 6444-4
and the remainder of Puller 6444 (Fig. 33).(3) Remove snap-ring holding the rear output shaft
bearing onto the output shaft.
(4) Use Collar 6444-8, Jaws 8271 and Puller Rods 6444-3 for 4X2 vehicles or Puller Rods 6444-4 for 4X4
vehicles with the remainder of Puller 6444 to remove the rear output shaft bearing from the output shaft. (5) Remove rear output shaft thrust washer fromthe output shaft.
Fig.33OUTPUTSHAFTPOCKETBEARING
1 - PULLER 2 - JAWS
INPUT SHAFT
(1) Remove fifth gear blocker ring from the input
(2) Remove fifth gear friction cone from the input
shaft (Fig. 34).
shaft (Fig. 35).
Fig.34FIFTHGEARBLOCKERRING
1 - FIFTH GEAR BLOCKER RING 2 - INPUT SHAFT
Fig.35FIFTHGEARFRICTIONCONE
1 - FRICTION CONE 2 - INPUT SHAFT
21 - 100 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 36).
DR
Fig.37INPUTSHAFTBEARING
1 - PULLER 2 - JAWS
Fig.36OUTPUTSHAFTPOCKETBEARINGRACE 1 - PULLER 2 - INPUT SHAFT
(4) Remove input shaft bearing and oil guide from the input shaft with Collar 6444-8, Jaws 8243, Puller Rods 6444-6 and the remainder of Puller 6444 (Fig. 37).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be installed backwards. Mark the gears, clutch gears, synchro hubs, and sleeves for installation reference during disassembly. Use paint or a scribe for mark- ing purposes. Then stack the geartrain parts in order of removal.
(1) Remove first gear from the output shaft. (2) Remove first gear bearing from the output
shaft (Fig. 38).
(3) Remove first gear blocker rings (2) and cones
from the 1-2 synchro assembly (Fig. 39).
(4) Install the remainder of the output shaft into
Fixture 8227 with press blocks under second gear.
(5) Install shaft and Fixture assembly into a shop
press (Fig. 40).
(6) Press second gear, 1-2 synchro assembly and
first gear bearing sleeve from the output shaft.
(7) Remove second gear bearing from the output
shaft.
Fig.38FIRSTGEARBEARING
1 - OUTPUT SHAFT 2 - FIRST GEAR BEARING
(8) Reverse output shaft in the Fixture 8227 with press blocks positioned under the 5-6 synchro assem- bly.
(9) Press the 5-6 synchro assembly from the out-
put shaft.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 101
(10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 41).
Fig.39FIRSTGEARBLOCKERRINGSAND
FRICTIONCONE
1 - OUTPUT SHAFT 2 - FIRST GEAR BLOCKER RINGS 3 - FIRST GEAR FRICTION CONE
Fig.41SIXTHGEARCOMPONENTS
1 - SIXTH GEAR FRICTION CONE 2 - SIXTH GEAR 3 - OUTPUT SHAFT 4 - SIXTH GEAR BLOCKER RING 5 - 5-6 SYNCHRO
Fig.40SECONDGEAR,1-2SYNCHRO&FIRST
GEARBEARINGSLEEVE
1 - OUTPUT SHAFT 2 - FIRST GEAR BEARING SLEEVE 3 - SECOND GEAR 4 - FIXTURE 5 - 1-2 SYNCHRO
21 - 102 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)COUNTERSHAFT
(1) Install the countershaft into Fixture 8227 with press blocks located under the fifth countershaft gear.
(2) Place the assembly into a shop press. (3) Use Guide 8235 on end of countershaft and press the countershaft fifth gear from the counter- shaft (Fig. 42).
DR
Fig.43SIXTHCOUNTERSHAFTGEAR
1 - GUIDE 2 - SIXTH COUNTER SHAFT GEAR 3 - FIXTURE
Fig.42FIFTHCOUNTERSHAFTGEAR
1 - GUIDE 2 - FIFTH COUNTER SHAFT GEAR 3 - FIXTURE
(4) Place countershaft in Fixture 8227 with press
blocks placed under the sixth countershaft gear.
(5) Use Guide 8235 on end of countershaft and press the countershaft sixth gear from the counter- shaft (Fig. 43).
(6) Remove countershaft from the press and Fix-
ture 8227.
(7) Remove fourth countershaft gear, friction cone, blocker ring and bearing from the countershaft (Fig. 44).
(8) Install countershaft
into Fixture 8227 with press blocks located under the third countershaft gear.
Fig.44FOURTHCOUNTERSHAFTGEAR
COMPONENTS
1 - FOURTH GEAR BLOCKER RING 2 - FOURTH GEAR BEARING 3 - COUNTERSHAFT 4 - FOURTH GEAR FRICTION CONE 5 - FOURTH COUNTERSHAFT GEAR
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 103
(9) Place assembly into a shop press and press third countershaft gear, 3-4 synchro and fourth coun- tershaft gear bearing sleeve from the countershaft (Fig. 45).
Fig.46THIRDGEARBEARING
1 - COUNTERSHAFT 2 - 2-3 THRUST WASHER 3 - THIRD COUNTERSHAFT GEAR BEARING
Fig.45THIRDCOUNTERSHAFTGEAR
COMPONENTS
1 - THIRD COUNTERSHAFT GEAR 2 - FIXTURE 3 - 3-4 SYNCHRO 4 - BEARING SLEEVE 5 - COUNTERSHAFT
(10) Remove countershaft from the press and Fix-
ture 8227.
(11) Remove third countershaft gear bearing from
the countershaft (Fig. 46).
(12) The 2-3 thrust washer should not normally need to be removed from the countershaft. If neces- sary slide 2-3 thrust washer off countershaft.
CLUTCH HOUSING
(1) Remove input shaft retainer bolts from the
clutch housing and remove retainer (Fig. 47).
Fig.47INPUTSHAFTRETAINER
1 - INPUT SHAFT RETAINER 2 - CLUTCH HOUSING
21 - 104 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(2) Remove countershaft oil guide from the coun- tershaft front bearing bore in the clutch housing (Fig. 48).
DR
Fig.49FRONTCOUNTERSHAFTBEARINGRACE 1 - CLUTCH HOUSING 2 - HANDLE 3 - REMOVER
Fig.48COUNTERSHAFTOILGUIDE
1 - CLUTCH HOUSING 2 - COUNTERSHAFT OIL GUIDE
(3) Remove countershaft front bearing race, end- play shims and spacer from the clutch housing with Remover 6061-1 and Handle C-4171 (Fig. 49).
(4) Remove input shaft bearing race with Remover/
Installer 8237 and Handle C-4171.
(5) Remove input shaft oil guide and retainer seal
(Fig. 50).
CLEANING - TRANSMISSION
Clean the gears, bearings shafts, extension/adapter housing and gear case with solvent. Dry all parts except the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and polished out with crocus cloth.
Inspect the reverse idler gear, bearings, shaft and thrust washers. Replace the bearings if the rollers are worn, chipped, cracked, flat-spotted or brinnelled. Replace the gear if the teeth are chipped, cracked or worn thin.
Inspect the front bearing retainer and bearing cup. Replace the bearing cup if scored, cracked, brinnelled
Fig.50OILGUIDEANDSEAL
1 - INPUT SHAFT OIL GUIDE 2 - INPUT SHAFT OIL SEAL
or rough. Check the release bearing slide surface of the retainer carefully. Replace the retainer if worn or damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap ring grooves and threads. Replace the shaft if any surfaces exhibit considerable wear or damage.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 105
Inspect the countershaft and bearings. Replace the shaft if any surfaces exhibit considerable wear or dam- age.
Inspect shift forks for wear and distortion. Check fit of the sleeve in the fork to be sure the two parts fit and work smoothly. Replace the fork if the roll pin holes are worn oversize or damaged. Do not attempt to salvage a worn fork. Replace shift fork roll pins if necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots, pit- ting or other damage. Replace the bearings if necessary. Inspect the blocker rings and fiction cones. replace either part if worn or damaged in any way. Replace if the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins. Replace the pins if bent or worn. Replace the wash- ers if worn or the locating pin notches are distorted. Inspect the case and housing/adapter sealing and mating surfaces are free of burrs and nicks. Inspcet the alignment dowels in the case top surface and in the housing/adapter are tight and in good condition. Replace the gear case or housing/adapter if cracked or broken.
ASSEMBLY
NOTE: Gaskets are not used in the transmission. Use Mopar Gasket Maker or equivalent on all gear case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Place second gear on bench with the synchro
clutch ring up.
(2) Install second gear synchro inner blocker ring
onto second gear (Fig. 51).
(3) Install second gear synchro friction cone over
the blocker ring and onto second gear (Fig. 52).
Fig.52FRICTIONCONE
1 - GEAR 2 - FRICTION CONE
(4) Install second gear synchro outer blocker ring over the second gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 53).
Fig.53OUTERBLOCKERRING
1 - OUTER BLOCKER RING 2 - LUG 3 - GEAR
Fig.51INNERBLOCKERRING
1 - INNER BLOCKER RING 2 - GEAR
21 - 106 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(5) Install 1-2 synchro assembly onto the second
gear assembly (Fig. 54).
DR
Fig.543-4SYNCHROASSEMBLY
1 - SYNCHRO 2 - GEAR
(6) Reverse assembly on the bench. (7) Lubricate and install second gear bearing into
second gear (Fig. 55).
Fig.56OUTPUTSHAFTINTO1-2SYNCHRO
1 - OUTPUT SHAFT 2 - 1-2 SYNCHRO 3 - SECOND GEAR
(13) Install first gear synchro friction cone over the
blocker ring and onto first gear (Fig. 52).
(14) Install first gear synchro outer blocker ring over the first gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 53).
(15) Reverse the output shaft in the press. (16) Install first gear bearing sleeve onto the out-
put shaft.
Fig.55SECONDGEARANDBEARING
1 - BEARING 2 - GEAR
(8) Place 1-2 synchro, second gear and second gear bearing assembly on shop press with second gear fac- ing upward.
(9) Install output shaft into the second gear 1-2
synchro assembly with the front of the output shaft facing upward (Fig. 56).(10) Press the output shaft into position. (11) Place first gear on bench with the synchro
clutch ring up.
(12) Install first gear synchro inner blocker ring
onto first gear (Fig. 51).
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 107
(17) Install first gear bearing sleeve the remainder of the way onto the output shaft using Installer 8228
and a shop press (Fig. 57).Fig.57FIRSTGEARBEARINGSLEEVE
1 - INSTALLER 2 - FIRST GEAR BEARING SLEEVE
Fig.58FIRSTGEARANDBLOCKERASSEMBLY
1 - OUTPUT SHAFT 2 - FIRST GEAR ASSEMBLY
(18) Install first gear and blocker assembly onto
the output shaft (Fig. 58).
(19) Install first gear bearing over the output shaft
and into first gear.
output shaft (Fig. 59).
(20) Install output shaft thrust washer onto the
Fig.59OUTPUTSHAFTTHRUSTWASHER
1 - OUTPUT SHAFT 2 - OUTPUT SHAFT THRUST WASHER
21 - 108 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(21) Install rear output shaft bearing onto the out- put shaft with Installer 8228 and a shop press (Fig. 60).
(22) Install a new snap-ring to hold the rear out- put bearing onto the output shaft. Install the thick- est snap-ring which will fit into the groove.
DR
Fig.61SIXTHGEAR
1 - SIXTH GEAR 2 - SIXTH GEAR BEARING
Fig.62SIXTHGEARBLOCKERRING
1 - SIXTH GEAR BLOCKER RING 2 - SIXTH GEAR FRICTION CONE
Fig.60REAROUTPUTSHAFTBEARING
1 - INSTALLER 2 - REAR OUTPUT SHAFT BEARING
(23) Reverse output shaft in the Fixture 8227 and support the shaft with press blocks under first gear. (24) Install sixth gear bearing onto the output
shaft.
gear.
(25) Install sixth gear onto the output shaft and
over the sixth gear bearing (Fig. 61).
(26) Install the sixth gear friction cone onto sixth
(27) Install sixth gear blocker ring over the sixth
gear friction cone (Fig. 62).
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 109
(28) Install Guide 8235 onto the end of the output
shaft (Fig. 63).
Fig.63OUTPUTSHAFTGUIDE
1 - GUIDE 2 - OUTPUT SHAFT
Fig.645-6SYNCHRO
1 - INSTALLER 2 - 5-6 SYNCHRO
(29) Install 5-6 synchro over Guide 8235 and onto
the output shaft.
(30) Press 5-6 synchro (Fig. 64) onto the output
shaft with Installer 8156 and a shop press.
(31) Install output shaft pocket bearing onto the
output shaft.
(32) Press pocket bearing the remainder of the way onto the output shaft using Guide 8235 and a shop press (Fig. 65).
(33) Install a new snap-ring to hold the output
shaft pocket bearing onto the output shaft.
Fig.65OUTPUTSHAFTPOCKETBEARING
1 - GUIDE 2 - POCKET BEARING
21 - 110 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)COUNTERSHAFT
DR
(1) Place third countershaft gear on the bench
with the synchro clutch ring up.
(2) Install third countershaft gear friction cone
onto third gear (Fig. 66).
Fig.683-4SYNCHROASSEMBLY
1 - SYNCHRO 2 - GEAR
Fig.66FRICTIONCONEANDTHIRDGEAR
1 - FRICTION CONE 2 - GEAR 3 - CLUTCH RING
(3) Install
third countershaft gear blocker ring
onto the friction cone (Fig. 67).
Fig.67BLOCKERRINGONTOFRICTIONCONE
1 - BLOCKER RING 2 - GEAR 3 - FRICTION CONE
(4) Install 3-4 synchro assembly onto the blocker
ring/gear assembly (Fig. 68).
(5) Reverse the assembly on the bench. (6) Install third countershaft gear bearing into the
third countershaft gear.
(7) Install 2-3 thrust washer onto the countershaft. (8) Place third gear/3-4 synchro assembly in a shop
press.
(9) Install countershaft through the third gear/3-4
(10) Press
countershaft
into
the 3-4 synchro
synchro assembly.
assembly (Fig. 69).
Fig.69COUNTERSHAFTINTO3-4SYNCHRO
1 - COUNTERSHAFT 2 - 2-3 THRUST WASHER 3 - THIRD COUNTERSHAFT GEAR
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 111
(11) Install fourth countershaft gear bearing sleeve
(19) Install countershaft into the fourth/sixth coun-
tershaft gear assembly in the shop press.
(20) Press countershaft into sixth gear (Fig. 71).
CAUTION: Gear and shaft must be aligned while pressing or the gear will bind on the shaft.
onto the output shaft.
(12) Press fourth countershaft bearing sleeve onto the countershaft with Installer 8228 and a shop press.
(13) Place fourth countershaft gear on the bench
with the synchro clutch ring up.
(14) Install fourth countershaft gear friction cone
onto fourth countershaft gear (Fig. 66).
(15) Install fourth countershaft gear blocker ring
onto the friction cone (Fig. 67).
(16) Install fourth countershaft gear bearing into
the fourth countershaft gear.
(17) Place sixth countershaft gear in the shop
press.
(18) Position fourth countershaft gear assembly
onto the sixth countershaft gear (Fig. 70).
Fig.70FOURTHCOUNTERSHAFTONTOSIXTH
COUNTERSHAFTGEAR
Fig.71COUNTERSHAFTINTOSIXTHGEAR
1 - FOURTH BEARING 2 - FOURTH COUNTERSHAFT GEAR 3 - SIXTH COUNTERSHAFT GEAR
1 - COUNTERSHAFT 2 - SIXTH COUNTERSHAFT GEAR 3 - 3-4 SYNCHRO
(21) Place fifth countershaft gear into the shop
press.
21 - 112 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(22) Install countershaft into the fifth countershaft gear and press countershaft into fifth gear (Fig. 72).
CAUTION: Gear and shaft must be aligned while pressing or the gear will bind on the shaft.
(23) Place front countershaft bearing onto the
countershaft. (24) Install
front countershaft bearing onto the countershaft with Installer 8236 and Handle C-4171. (25) Install a new snap-ring to hold the front
countershaft bearing onto the countershaft.
(26) Place rear countershaft bearing onto the coun-
tershaft.
INPUT SHAFT
(1) Place the input shaft bearing onto the input
shaft.
(2) Install
input MD998805 (Fig. 73).
shaft bearing with Installer
Fig.72COUNTERSHAFTTOFIFTH
COUNTERSHAFTGEAR
1 - COUNTERSHAFT 2 - FIFTH COUNTERSHAFT GEAR
Fig.73INPUTSHAFTBEARING
1 - INSTALLER 2 - INPUT SHAFT BEARING
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 113
(3) Position the input shaft bearing oil guide on
the input shaft (Fig. 74).
Fig.75OUTPUTSHAFTPOCKETBEARINGRACE 1 - HANDLE 2 - INPUT SHAFT 3 - INSTALLER
Fig.74INPUTSHAFTOILGUIDE
1 - INPUT SHAFT 2 - INPUT SHAFT OIL GUIDE
(4) Install
input shaft bearing oil guide with
Installer MD998805.
the input shaft.
(5) Place the output shaft pocket bearing race in
(6) Install output shaft pocket bearing race into the input shaft with Installer C-4628 and Handle C-4171 (Fig. 75).
CLUTCH HOUSING
(1) Install
input shaft bearing race so that the bearing race protrudes 0.3 in. above the front surface of the clutch housing. Install bearing race with Remover/Installer 8237 and Handle C-4171.
(2) Install countershaft front bearing race into the clutch housing so that the bearing race protrudes 0.4
in. above the front surface of the clutch housing. Install bearing race with Remover 6061-1 and Han- dle C-4171.(3) Install countershaft oil guide and spacer into the countershaft front bearing bore in the clutch housing (Fig. 76).
(4) Clean all old sealer from the input shaft retainer and the clutch housing but DO NOT apply
Fig.76OILGUIDEANDSPACER
1 - 0.3 IN. BEYOND FLUSH 2 - 0.4 IN. BEYOND FLUSH
new sealer at this time. New sealer will be applied after all the preload measurements are made and end-play shims are installed.
21 - 114 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
NOTE: Do not replace the input shaft seal at this time. A new seal will be installed after all the pre- load measurements are made and endplay shims are installed.
(5) Install
input shaft retainer onto the clutch housing and install bolts to hold the input shaft retainer.
GEARTRAIN
(5) Install countershaft into the Support Stand 8246 and verify that all gears are meshed with their mates on the output shaft (Fig. 78).
(1) Install input shaft into Support Stand 8246. (2) Install fifth gear friction cone onto the input
(3) Install fifth gear blocker ring onto the fifth
gear friction cone.
(4) Install output shaft into the input shaft (Fig.
shaft.
77).
Fig.78COUNTERSHAFTWITHOUTPUTSHAFT
1 - COUNTERSHAFT 2 - OUTPUT SHAFT 3 - SUPPORT STAND
Fig.77OUTPUTSHAFTANDINPUTSHAFT
1 - OUTPUT SHAFT 2 - INPUT SHAFT 3 - SUPPORT STAND
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 115
(6) Install Fixture 8232 to the output shaft and
countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro and tighten the screw to hold the 5-6 synchro together during the remainder of the installation pro- cedure.
(8) Attach a engine crane or equivalent to Fixture 8232 and move the geartrain from the Support Stand 8246 to the clutch housing (Fig. 79).
Fig.80SHIFTRAILSINSTALLED
1 - SHIFT RAILS
(11) With the geartrain approximately 1/4 in. from the clutch housing, remove Holding Tool 8242 from the 5-6 synchro (Fig. 81).
Fig.79GEARTRAINFIXTURE
1 - FIXTURE 2 - SUPPORT STAND
(9) Install shift forks and rails onto the geartrain
(Fig. 80).
NOTE: The closest shift arm to the geartrain is for Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.(10) Install geartrain and shift rails into the clutch housing. Lower the geartrain and rails into the hous- ing slowly while guiding input shaft through input shaft seal. Avoid any binds on the shift rails, forks and synchros as the rails enter their bushings.
Fig.81HOLDINGTOOL
1 - HOLDING TOOL 2 - 5-6 SYNCHRO
CAUTION: Do not damage input shaft seal with the input shaft splines.
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.
21 - 116 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts and
tighten to 28 N·m (20 ft. lbs.) (Fig. 82).
Fig.825-6CROSSOVERBRACKETBOLTS
1 - 5-6 CROSSOVER BRACKET
Fig.83LIFTFIXTURE
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
1 - FIXTURE 2 - TRANSMISSION CASE
TRANSMISSION GEAR CASE
(1) Install rear output shaft bearing race into the transmission gear case with Installer C-4308 and Handle C-4171.
(2) Install rear countershaft bearing race into the transmission gear case with Installer 8153 and Han- dle C-4171.
(3) Install Fixture 8232 to the transmission gear
case.
NOTE: Shift socket must be loose on the shift shaft and is rotated a minimum of 90° from its normal position. This will ensure enough clearance to install the transmission gear case.
(4) Apply sealant to the clutch housing. (5) Attach an engine crane or equivalent to Fixture 8232 and install the transmission gear case onto the clutch housing (Fig. 83).
(6) Install clutch housing bolts and tighten to 48
N·m (35 ft.lbs.).
(7) Install shift socket roll pin with a suitable 6
mm (7/32 in.) punch and hammer.
MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use Socket 6993 to rotate the shafts and seat the bear- ings.
(2) Measure mainshaft endplay with Dial Indicator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case (Fig. 84).
Fig.84MEASUREMAINSHAFTENDPLAY
1 - DIAL INDICATOR 2 - EXTENSION ROD 3 - MAIN SHAFT
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 117
(3) Measure countershaft end-play with Dial Indi- cator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case (Fig. 85).
Fig.86REVERSESHIFTFORKANDSYNCHRO
1 - REVERSE SYNCHRO 2 - REVERSE SHIFT FORK
(2) Install roll-pin securing the reverse shift fork to the reverse shift rail with 6 mm (7/32 in.) punch and a hammer.
(3) Install reverse gear bearing sleeve onto the output shaft with Installer 6446 if necessary (Fig. 87).
Fig.85MEASURECOUNTERSHAFTEND-PLAY
1 - EXTENSION ROD 2 - DIAL INDICATOR 3 - COUNTERSHAFT
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play of 0-0.10 mm (0-0.004 in.) for the mainshaft and countershaft.
NOTE: Countershaft shims go between the bearing race and spacer. Mainshaft shims go into the input shaft retainer.
(6) Install a new input shaft seal into the input
shaft retainer with Installer C-4965.
(7) Install input shaft oil guide with C-3972-A and
Handle C-4171.
(8) Apply sealer to the input shaft retainer and install retainer onto the clutch housing. Install bolts and tighten to 28 N·m (20 ft.lbs.).
REVERSE GEAR
(1) Install reverse shift fork and synchronizer as an assembly onto the reverse shift rail and output shaft (Fig. 86).
NOTE: Raised square shoulder and snap-ring on the synchro face the case.
Fig.87REVERSEBEARINGSLEEVE
1 - REVERSE GEAR BEARING SLEEVE
21 - 118 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)(4) Install reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring and reverse gear bearing (Fig. 88).
DR
Fig.89OUTPUTSHAFTBEARINGANDTHRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING 2 - THRUST WASHER
(11) Install reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer onto the idler gear shaft.
(12) Install
idler and reverse countershaft gears
together (Fig. 90).
Fig.88REVERSEGEARCOMPONENTS
1 - REVERSE GEAR 2 - REVERSE BEARING 3 - BLOCKER RING 4 - FRICTION CONE
(5) Install output shaft ball bearing assembly and reverse thrust washer onto the output shaft (Fig. 89).
NOTE: Raised shoulder on thrust washer faces away from the reverse gear.
Fig.90REVERSEIDLERANDCOUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR 2 - COUNTERSHAFT REVERSE GEAR
(6) Install a new output shaft nut onto the output
shaft.
(7) With Wrench 8226 on the output shaft nut and Socket 6993 or 6984 holding the output shaft, tighten the nut to 339 N·m (250 ft.lbs.).
(8) Stake nut into the slot in the output shaft with
a 9 mm (5/16 in.) punch.
(9) Press countershaft reverse gear into the sleeve
with a shop press.
(10) Install reverse countershaft rear bearing onto the countershaft reverse gear assembly with Installer C-4652 and Handle C-4171.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 119
(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
Fig.91CROSSOVERCAMROLLERSANDPIN
1 - CROSSOVER CAM PIN 2 - CROSSOVER CAM ROLLERS
EXTENSION/ADAPTER HOUSING
Fig.92MeasureHeightofReverseCountershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
extension
(1) Install
bushing with Installer 8156 and Handle C-4171, if necessary. The oil feed hole must be at the 12 o’clock position when installed.
housing
(2) On 4X2 vehicles, install extension housing seal with Installer 8154 and Handle C-4171, with the weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion of toward the ground) when installed.
face downward (
the seal must
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install
the crossover cam bushing into the extension/adapter housing with Installer 8239 and Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(10) Place Gauge Bar 6311 across the housing face. Measure the distance from the top of the bar to the bottom of the reverse countershaft bearing race bore (Fig. 93).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.
Fig.93MEASUREDEPTHOFREVERSE
COUNTERSHAFTGEARBEARINGRACEBORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
(12) The difference between the two measurements is the end-play for the reverse countershaft gear assembly. (13) Install shims to achieve 0.15-0.25 mm (0.006- 0.010 in.) end-play for the reverse countershaft gear assembly into the reverse countershaft bearing race bore.
21 - 120 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
(14) Use Installer to install the reverse counter- shaft bearing race into the extension/adapter hous- ing.
(15) Install back-up lamp switch into the exten- sion/adapter housing and tighten to 28 N·m (20
ft.lbs.).(16) Install
crossover
cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 94).
(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter housing onto the transmission gear case. Tighten bolts to 48 N·m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N·m (41 ft.lbs.).
(23) Install primary shift
rail detent plunger, spring and plug into the transmission case. Tighten detent plug to 47.5 N·m (35 ft.lbs.).
(24) Install shift tower onto the transmission case
and tighten bolts to 9 N·m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com- ponents supplied with the transmission. If a new shift tower is supplied with the new transmission, do not re-use the original shift tower.
(1) Apply a light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of following components:
†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 bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
in clutch disc hub.
(4) Raise transmission until input shaft is centered
(5) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(6) Work transmission forward until seated against engine block. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
and
tighten transmission-to-engine
(7) Install block bolts.
(8) Install clutch slave cylinder. (9) Connect backup light switch wires. (10) Position transmission harness wires in clips
on transmission.
rear crossmember.
(11) Install transmission mount on transmission or
(12) Install rear crossmember. (13) Remove transmission jack and engine support
fixture.
(14) Fill transmission with required lubricant (Fig. case if
in transfer
level
96). Check lubricant equipped.
Fig.94CROSSOVERCAMBOLT
1 - CROSSOVER CAM 2 - BOLT 3 - EXTENSION HOUSING
(18) Install crossover detent plunger, spring and plug into the extension/adapter housing. Tighten the plug to 47.5 N·m (35 ft.lbs.) (Fig. 95).
Fig.95CROSSOVERCAMDETENTPLUG
1 - DETENT PLUG 2 - EXTENSION HOUSING
(19) Apply sealer to the surface of the transmis-
sion case.
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 121
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
(3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts to 41-47 N·m (30-35 ft. lbs.) if case has 3/8 studs. If case has 5/16 studs tighten to 30-41 N·m (22-30 ft. lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.
aligned.
(6) Install propeller shafts with reference marks
(7) Install transfer case skid plate,
if equipped, and crossmember. Tighten attaching bolts/nuts to 41
N·m (30 ft. lbs.).(8) Install exhaust system components. (9) Remove support and lower vehicle. (10) Shift transmission into third gear. (11) Clean the mating surfaces of shift tower, iso- lator plate and transmission case with suitable wax and grease remover.
(12) Apply Mopar Gasket Maker or equivalent to the sealing surface of the transmission case. Do not over apply sealant.
(13) Install
isolator plate onto the transmission
case, metal side down.
(14) Install shift tower onto the isolator plate. No sealant is necessary between the shift tower and top of isolator plate.
(15) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(16) Install the bolts to hold the shift tower to the isolator plate and the transmission case. Tighten the shift tower bolts to 10.2-11.25 N·m (7.5-8.3 ft. lbs.).
(17) Install shift lever boot and bezel.
Fig.96FILLPLUG
1 - FILL PLUG
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components. (3) Remove support and lower vehicle. (4) Shift transmission into third gear. (5) Clean the mating surfaces of shift tower and isolator plate with suitable wax and grease remover. (6) Apply Mopar Gasket Maker or equivalent to sealing surface of the transmission case. Do not over apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No sealant is necessary between the shift tower and top of isolator plate.
(9) Verify shift tower, isolator plate and the shift
socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso- lator plate and the transmission case. Tighten bolts to 10.2–11.25 N·m (7.5–8.3 ft. lbs.). (11) Install shift boot and bezel.
21 - 122 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued) SPECIFICATIONS - NV5600TORQUE SPECIFICATIONS
DR
DESCRIPTION
Plug, Crossover Cam and Detent
Bolt, Input Retainer
Bolt, 5-6 Crossover Bracket
Bolt, Clutch Housing
Bolt, Extension/Adapter Housing
Bolt, Shift Tower
Switch, Back-up Lamp
Bolt, Shift Blocker Bolt, PTO Cover
Pivot, Clutch Release Lever
Plug, Fill
Nut, Output Shaft
SPECIAL TOOLS
N·m 48
28
28
48
48
28
55
40
22
30
339Ft. Lbs.
In. Lbs.
35
20
20
35
35
20
41
30
16
22
25080
REMOVER8155
INSTALLER8156
HANDLEC-4171
INSTALLERC-3972-A
INSTALLER8154
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 123
WRENCH8226
JAWS6451
SOCKET6984
INSTALLER6061
SOCKET6984
INSTALLER6448
PULLER6444
INSTALLERC-4308
JAWS6447
RODEXTENSION8161
21 - 124 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
FIXTURE8227
REMOVER8233
INSTALLER8228
REMOVER8234
FIXTURE8230
GUIDE8235
FIXTURE8232
INSTALLER8236
DR MANUAL TRANSMISSION - NV5600 (Continued)
MANUAL TRANSMISSION - NV5600
21 - 125
INSTALLER/REMOVER8237
FIXTURE8241
INSTALLER/REMOVE8238
HOLDING8242
INSTALLER8239
REMOVER8243
REMOVER8240
PULLER8244
21 - 126 MANUAL TRANSMISSION - NV5600
MANUAL TRANSMISSION - NV5600 (Continued)DR
REMOVER8245
DIALINDICATORC-3339
INSTALLERC-4965
SUPPORTSTAND8246
REMOVERL-4418
REMOVER8262
PULLERC-293-PA
ADAPTERSC-293-52
REMOVER8271
INSTALLERMD998805
DR
MANUAL TRANSMISSION - NV5600
21 - 127
ADAPTER HOUSING SEAL REMOVAL
INSTALLATION
(1) Install
extension
housing
bushing with
Installer 8156 and Handle C-4171 (Fig. 98).
(1) Raise and support vehicle. (2) Mark propeller shaft and yokes for installation
reference and remove shaft.
(3) Remove the transfer case. (4) Remove the adapter housing seal with a pry
tool or slide hammer with a screw.
INSTALLATION
Handle C-4171.
(1) Install adapter housing seal with Installer and
(2) Install transfer case. (3) Install propeller shaft with reference marks
aligned.
(4) Check fluid level. (5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL REMOVAL
(1) Mark propeller shaft and pinion yoke for installation reference and remove the propeller shaft. (2) Remove extension housing seal with a pry tool
or a slide hammer and screw.
(3) Remove
extension
housing
bushing with
Remover 8155 (Fig. 97).
Fig.97EXTENSIONHOUSINGBUSHINGREMOVAL 1 - REMOVER
Fig.98InstallExtensionHousingBushing
1 - HANDLE 2 - INSTALLER 3 - BUSHING
(2) Install extension housing seal with Installer
8154 and Handle C-4171 (Fig. 99).
Fig.99EXTENSIONHOUSINGSEALINSTALLER
1 - INSTALLER 2 - HANDLE
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
21 - 128 MANUAL TRANSMISSION - NV5600
DR
SHIFT COVER REMOVAL
(1) Shift transmission into Neutral. (2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(5) Remove the shift tower (Fig. 100) and isolator
plate (Fig. 101) from the transmission.
Fig.100SHIFTTOWER
1 - SHIFT TOWER 2 - TRANSMISSION
Fig.101SHIFTTOWERISOLATORPLATE
1 - ISOLATOR PLATE 2 - TRANSMISSION
INSTALLATION
(1) Shift transmission into third gear. (2) Clean the mating surfaces of shift tower, isola- tor plate and transmission gear case with suitable wax and grease remover.
(3) Apply Mopar Gasket Maker or equivalent to the sealing surface of the transmission. Do not over apply sealant.
(4) Install
isolator plate onto the transmission,
metal side down.
(5) Install shift tower onto the isolator plate. No sealant is necessary between the shift tower and iso- lator plate.
(6) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(7) Install shift tower bolts and tighten the shift
tower bolts to 8-10 N·m (7-9 ft. lbs.).
(8) Install shift lever extension, shift boot and
bezel.
DR
AUTOMATIC TRANSMISSION - 46RE
21 - 129
AUTOMATIC TRANSMISSION - 46RE
TABLE OF CONTENTS
page
page
AUTOMATIC TRANSMISSION - 46RE
ELECTRONIC GOVERNOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 131
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 139
DIAGNOSIS AND TESTING - PRELIMINARY . . 139
DIAGNOSIS AND TESTING - ROADTESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 140
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 143
DIAGNOSIS AND TESTING - CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 196
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 196
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 199EXTENSION HOUSING BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 200EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 200FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL . . . . . . . . . . . . . 201
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . 143
DIAGNOSIS AND TESTING - CAUSES OF
DIAGNOSIS AND TESTING - DIAGNOSIS
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 201
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
DIAGNOSIS AND TESTING - FLUID
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . 156
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 158
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 165
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 173
SCHEMATICS AND DIAGRAMSHYDRAULIC SCHEMATICS . . . . . . . . . . . . . 175
SPECIFICATIONS TRANSMISSION
SPECIAL TOOLS
. . . . . . . . . . . . . . . . . . . . . 187
RE TRANSMISSION
. . . . . . . . . . . . . . . . . . 189
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 201
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . 203
STANDARD PROCEDURE - TRANSMISSION
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
FRONT CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 204
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 204
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 205
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 206
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 206ACCUMULATOR
FRONT SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 191
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 192
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 192BANDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 193
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 193
ADJUSTMENTSADJUSTMENT - BANDS
. . . . . . . . . . . . . . . 193
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 194
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 194
DIAGNOSIS AND TESTING - BRAKETRANSMISSION SHIFT INTERLOCK . . . . . . 195
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK
. . . . . . . . . . . . . . . . . . . 195
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 207
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 208
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 208
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 208
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 209GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 210
ADJUSTMENTSGEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . 211
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 212
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 212
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 21221 - 130
AUTOMATIC TRANSMISSION - 46RE
DR
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 214
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 215OUTPUT SHAFT FRONT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 217REAR SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 252
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 252
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 252
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 253OUTPUT SHAFT REAR BEARING
SHIFT MECHANISM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 217DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 253
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 253OVERDRIVE CLUTCH
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 218
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 218DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 253
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 254OVERDRIVE SWITCH
SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 218
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 218
DIAGNOSIS AND TESTING - OVERDRIVEELECTRICAL CONTROLS
. . . . . . . . . . . . . . 219
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 219DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 254
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 254THROTTLE VALVE CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 254
ADJUSTMENTS - THROTTLE VALVECABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
OVERDRIVE UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 220
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 227
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 236OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 237
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 237
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 238
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 238
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 239PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 241
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 241PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 242
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 243
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 243
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 245
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 245REAR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 248
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 249
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 249
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 250
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 250TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 257
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 261
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 262TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 262
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 262
STANDARD PROCEDURE - TORQUECONVERTER DRAINBACK VALVE . . . . . . . . 262
TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 263
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 263
DIAGNOSIS AND TESTING - TRANSMISSIONRANGE SENSOR (TRS)
. . . . . . . . . . . . . . . . 264
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 266TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 267
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 267VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 267
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 272
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 287
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 298
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 307
. . . . . . . . . . . 308
ADJUSTMENTS - VALVE BODYDR
AUTOMATIC TRANSMISSION - 46RE
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AUTOMATIC TRANSMISSION - 46RE DESCRIPTION
The 46RE (Fig. 1) is a four speed fully automatic transmissions with an electronic governor. The 46RE is equipped with a lock-up clutch in the torque con- verter. First through third gear ranges are provided by the clutches, bands, overrunning clutch, and plan- etary gear sets in the transmission. Fourth gear range is provided by the overdrive unit that contains an overdrive clutch, direct clutch, planetary gear set, and overrunning clutch.
The transmission contains a front, rear, and direct clutch which function as the input driving compo- nents. It also contains the kickdown (front) and the
low/reverse (rear) bands which, along with the over- running clutch and overdrive clutch, serve as the holding components. The driving and holding compo- nents combine to select the necessary planetary gear components, in the front, rear, or overdrive planetary gear set, transfer the engine power from the input shaft through to the output shaft.
The valve body is mounted to the lower side of the transmission and contains the valves to control pres- sure regulation, fluid flow control, and clutch/band application. The oil pump is mounted at the front of the transmission and is driven by the torque con- verter hub. The pump supplies the oil pressure nec- essary for clutch/band actuation and transmission lubrication.
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AUTOMATIC TRANSMISSION - 46RE (Continued)AUTOMATIC TRANSMISSION - 46RE
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DR AUTOMATIC TRANSMISSION - 46RE (Continued)
AUTOMATIC TRANSMISSION - 46RE
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1 - TORQUE CONVERTER 2 - INPUT SHAFT 3 - OIL PUMP 4 - FRONT BAND 5 - FRONT CLUTCH 6 - REAR CLUTCH 7 - PLANETARIES 8 - REAR BAND 9 - OVERRUNNING CLUTCH 10 - OVERDRIVE CLUTCH
11 - DIRECT CLUTCH 12 - PLANETARY GEAR 13 - OUTPUT SHAFT 14 - SEAL 15 - INTERMEDIATE SHAFT 16 - OVERDRIVE OVERRUNNING CLUTCH 17 - DIRECT CLUTCH SPRING 18 - OVERDRIVE PISTON RETAINER 19 - FILTER 20 - VALVE BODY
IDENTIFICATION
Transmission identification numbers are stamped on the left side of the case just above the oil pan gas- ket surface (Fig. 2). Refer to this information when ordering replacement parts.
Fig.2TransmissionPartAndSerialNumber
Location
1 - PART NUMBER 2 - BUILD DATE 3 - SERIAL NUMBER
GEAR RATIOS
The 46RE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69:1
Rev. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21OPERATION
The application of each driving or holding compo- nent is controlled by the valve body based upon the manual lever position, throttle pressure, and gover- nor pressure. The governor pressure is a variable pressure input to the valve body and is one of the signals that a shift is necessary. First through fourth gear are obtained by selectively applying and releas- ing the different clutches and bands. Engine power is thereby routed to the various planetary gear assem- blies which combine with the overrunning clutch assemblies to generate the different gear ratios. The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is con- trolled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch can also be engaged in the manual second gear position if high transmission temperatures are sensed by the PCM. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. The torque converter clutch feature increases fuel economy and reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear only and the direct clutch is applied in all ranges except fourth gear, the transmission operation for park, neutral, and first through third gear will be described first. Once these powerflows are described, the third to fourth shift sequence will be described.
AUTOMATIC TRANSMISSION - 46RE
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AUTOMATIC TRANSMISSION - 46RE (Continued) PARK POWERFLOWNEUTRAL POWERFLOW
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With the gear selector in the NEUTRAL position (Fig. 4), the power flow of the transmission is essen- tially the same as in the park position. The only operational difference is that the parking sprag has been disengaged, unlocking the output shaft from the transmission case and allowing it to move freely.
As the engine is running and the crankshaft is rotating, the flexplate and torque converter, which are also bolted to it, are all rotating in a clockwise direction as viewed from the front of the engine. The notched hub of the torque converter is connected to the oil pump’s internal gear, supplying the transmis- sion with oil pressure. As the converter turns, it turns the input shaft in a clockwise direction. As the input shaft is rotating, the front clutch hub-rear
