Download Section XI - Transmission

CHRYSLER SERVICE MANUAL
EXTENSION HOUSING
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BEARING
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TRANSMISSION—249
case for wear. I f installation of a new bearing
does not correct condition, install a new shaft
or case.
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TOOL
57x166
Fig. 4—Removing Extension Housing Rear Bearing
NOTE: If condition of needle and ball bearings
warrant their removal proceed as follows:
Remove needle bearing using Tool C-3275 bydriving bearing into extension housing. W i t h
needle bearing laying i n extension housing,
drive ball bearing out of its bore, using driver,
Tool C-3275 as shown i n Figure 4. Needle
bearing can now be removed through rear of
extension housing.
e. Reverse Idler
Using a suitable brass drift, drive reverse
gear shaft towards rear of transmission
Remove locking key from keyway. Finish
ing out of shaft and l i f t out reverse idler
and bearing assembly.
idler
case.
drivgear
1 Countershaft
Check end play of the countershaft (.004-.012
inch permissible end play—refer to Paragraph
3 ) , to determine need for new thrust washers
at assembly. Using adapter arbor, Tool C-578,
drive countershaft toward rear and out of
transmission case. A key at end of shaft prevents the shaft from turning. Remove key. Remove adapter shaft ( w i t h adapter arbor i n stalled) from transmission case. Disassemble
countershaft assembly by removing thrust
washers, rollers and spacer.
2. INSPECTION
Before inspecting, wash each part thoroughly
in a suitable solvent, then dry. Clean mainshaft
and drive pinion shaft bearings. D r y by applying compressed air directly through bearing.
Never spin bearing with compressed air. Apply
a little o i l and t u r n bearing several times by
hand. Check bearings for looseness or noise by
comparing them w i t h a new^ bearing. (Be sure
to wash grease from new bearing. Apply a little
oil before making comparison test).
Inspect fit of bearings on their respective
shafts and i n bores. Inspect bearings, shaft, and
Inspect mainshaft splines for galling or scoring. Inspect bearing mounting surfaces and
snap r i n g grooves. Slight nicks or burrs can
be stoned off. Replace damaged parts. Inspect
the gear teeth and threads on inner and outer
synchronizer stop rings. Check gear teeth on
clutch gear sleeve.
I f there is evidence of chipped or excessively
worn gear teeth, replace the part. Make sure
synchronizer clutch sleeve slides freely on clutch
gear. Check pins of inner and outer synchronizer stop r i n g assembly for straightness and
looseness. The pins should be 1.570 to 1.580
inches long. I f pins do not comply w i t h this
specification, replace synchronizer stop r i n g
assemblies.
Replace countershaft gear cluster, i f any of
its gear teeth are broken, chipped or excessively
worn. Small nicks or burrs can be stoned off.
Check rollers for chips and nicks. Replace all
rollers i f any one is damaged. Check condition
of thrust washers, and replace i f excessive wear
is evident. Inspect the clutch teeth of the drive
pinion. I f they are excessively worn, broken,
or chipped, install a new pinion shaft. Inspect
mainshaft pilot rollers for p i t t i n g or scoring.
I f any of these conditions exist, replace all
roller bearings.
I f roller bearings fall out during disassembly, they are too loose and should be replaced.
Inspect gearshift housing and operating levers.
Replace rubber grommets i n operating levers,
i f worn or torn. Check interlock sleeve for free
movement i n its bore. Examine interlock balls
for corrosion. I f operating lever shaft detents
show signs of wear, replace shaft. Check shift
forks for free movement i n shaft lever. Check
general condition of transmission case and extension housing. Check all threaded holes and
plugs for stripped or pulled threads. Check all
mating and gasket surfaces for roughness and
scratches. Inspect castings for small cracks and
sand holes.
3. ASSEMBLY OF TRANSMISSION
a. Mainshaft
Before assembling the transmission, lubricate each part w i t h clean S.A.E. 80 lubricant.
Drive mainshaft rear bearing (ball) into bore
at rear of extension housing using driver, Tool