MANUAL TRANSMISSION NSG370 - Service Information

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

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

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

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

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

Shift component damage, clutch adjustment, worn pressure plate or disc are also causes of increased shift effort. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchronizer rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear-in.

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

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

1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug (1) and drain fluid.

3. Install drain plug and remove fill plug (1). 4. Fill transmission with 1.5 L (3.17 pts.) of Mopar® Manual Transmission Lubricant MS-9224 or to the bottom of the fill plug (1) hole.

1. Disconnect negative battery cable. 2. Remove the console manual shift bezel. Refer to REMOVAL .

3. Remove the floor console. Refer to REMOVAL .

4. With vehicle in neutral, position vehicle on hoist. 5. Remove drain plug (1) and drain fluid.

6. Mark installation reference marks on propeller shaft/shafts and remove shafts. 7. Remove transfer case shift cable, wiring connector and vent hose, if equipped. 8. Remove transfer case (1) from transmission (2), if equipped.

9. Support transmission with jack. 10. Remove transmission mount (1) bolts and crossmember (2) bolts. Remove transmission mount (1) with crossmember (2).

11. Vehicles with 3.7L engine, remove exhaust pipe with converters (3).

12. Remove clutch slave cylinder nuts (1) and remove cylinder (2).

13. Remove backup lamp switch (1) wiring connector (2).

14. Remove starter bolts and remove starter. 15. Remove transmission bolts (1,2,3) on 3.7L engine and remove transmission.

16. Remove transmission bolts (1,2,3) on 2.8L diesel engine and remove transmission.

1. Remove shift tower (1) bolts (2) and remove tower.

2. Through shift tower opening (1) shift two shift rails (2) forward to engage two gears.

3. Remove back-up lamp switch (1) bolt (2) and remove switch.

4. Remove countershaft plug (1) from the front housing (2) with a seal pick.

5. Remove countershaft bolt (1) from the front housing (2).

6. Remove output shaft (1) seal (2) from rear housing (3) with a seal pick.

7. Remove output shaft (1) snap ring (2) 4x4 only.

8. Stand transmission on the rear housing and remove the housing bolts. 9. Remove front housing (1) from the rear housing (2).

10. Remove shift rails (1) support plate (2) bolts.

11. Remove input shaft (1) roller bearing (2).

12. Remove fifth gear synchronizer blocker ring (1) from 5-6 synchronizer hub (2).

13. Remove fifth gear synchronizer friction ring (1) from 5-6 synchronizer hub (2).

14. Set geartrain and shift rails with rear housing into Fixture 9633. 15. Remove mainshaft (1) from rear housing bearing with Remover/Installer 9636 (2).

16. Remove mainshaft (1), countershaft (2) and shift rails/forks (3) from fixture.

1. Clamp build Fixture 9648 in a vise. Install mainshaft with 5-6 synchronizer facing up in build Fixture 9648. 2. Push 5-6 synchronizer sleeve (1) down on hub and remove detents (2) springs and balls.

3. Remove 5-6 synchronizer sleeve (1) from synchronizer hub (2).

4. Remove 5-6 synchronizer hub (1) snap ring (2) and record location.

NOTE: All snap rings are select fit from the factory, and must be installed in their original location.

5. Remove 5-6 synchronizer hub (1) and sixth gear synchronizer rings (2) with a three jaw puller. Place puller jaws under sixth gear synchronizer rings (2).

6. Remove sixth gear (1) and bearing (2).

7. Third gear (1) and fourth gear (2) are serviced with the mainshaft only. 8. Remove mainshaft from Fixture 9648. Turn fixture over in vise and set opposite end of mainshaft into the fixture.

9. Remove reverse gear (1) synchronizer sleeve (2) off synchronizer hub.

10. Remove reverse synchronizer hub (1) detents (2).

11. Remove reverse synchronizer hub (1) with three jaw puller (2). Place puller jaws in hub detent openings.

12. Remove reverse gear (1) synchronizer ring (2).

13. Remove reverse gear (1) and bearing (2).

14. Remove reverse gear bearing race (1), thrust washer (2) and first gear (3) with puller (4). Place puller jaws under first gear (3). 15. Remove first gear bearing.

16. Remove first gear synchronizer rings. 17. Push 1-2 synchronizer sleeve down on synchronizer hub (1) detents (2), balls and springs.

18. Remove 1-2 synchronizer sleeve (1) from synchronizer hub (2).

19. Remove 1-2 synchronizer hub (1) snap ring (2).

NOTE: All snap rings are select fit from the factory, and must be installed in their original location.

20. Remove 1-2 synchronizer hub (1), synchronizer rings and second gear (2) off shaft with a press. Place second gear (2) on press plates and press shaft through 1-2 synchronizer hub (1), synchronizer rings and second gear (2)

The countershaft (1) and 3-4 synchronizer (2) are serviced as an assembly only.

1. Remove input shaft retainer bolts (2) and remove retainer (1).

2. Remove countershaft bearing (1) retainer (2) bolts and remove retainers.

3. Remove countershaft bearing (1) from housing (2) with a hammer and driver.

4. Remove input shaft (1) bearing retainer bolts and remove retainers (2, 3). 5. Remove input shaft and bearing from housing with a dead blow hammer.

6. Remove input shaft seal (1) from housing (2) with a hammer and driver.

1. Remove input shaft bearing (1) snap ring (2).

NOTE: All snap rings are select fit from the factory, and must be installed in their original location.

2. Remove input shaft bearing (1) from input shaft with a Splitter 1130 (2) and press. Place splitter around bearing retainer lip and press input shaft through the bearing.

1. Remove reverse idler gear shaft bolt (1) from housing (2).

2. Thread idler gear shaft bolt (1) into the shaft (2). Then work shaft (2) out of the idler gear.

3. Remove reverse idler gear (1) shaft support (2).

4. Remove reverse idler gear (1) thrust washer (2).

5. Remove reverse idler gear (1) and bearing (2).

6. Break plastic countershaft roller bearing cage (1) with a screw driver (2). Then remove cage and roller bearing.

7. Remove countershaft roller bearing shell (1) from the rear housing with Remover 7794-A (2) and Slide Hammer C-637.

8. Remove mainshaft bearing (1) retainer bolts and remove retainers (2). 9. Remove bearing from housing with a hammer and driver.

Clean gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed air.

Clean shaft bearings with a mild solvent such as Mopar™ degreasing solvent or similar solvents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.

NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and polished out with crocus cloth.

Bearings: Inspect for worn, cracked, flat-spotted or brinnelled.

Gears: Inspect for worn, chipped or cracked teeth. Inspect bearing surfaces for ware or flat-spotted.

Mainshaft: Inspect for worn splines, snap ring grooves and threads. Inspect bearing surfaces for ware or flat- spotted. Third gear (1) and fourth gear (2) are serviced with mainshaft only.

Countershaft: Inspect for worn, chipped or cracked teeth. Inspect bearing surfaces (1) for wear or flat-spots. Inspect 3-4 synchronizer assembly (2). Inspect oil slinger for cracks. The countershaft is serviced as an

Oil Slinger: Inspect first/reverse oil slinger for cracks.

Input Shaft: Inspect for worn, chipped or cracked teeth (1). Inspect bearing surface (2) for wear or flat-spots. Inspect for worn splines (3).

Synchronizer components: Inspect for worn, chipped or cracked teeth (1) and burned friction surface (2) or flaking off friction material (3). Synchronizers are serviced as an assembly. 3-4 synchronizer assembly is serviced with countershaft.

Shift forks: Inspect shift forks and shoes (1) for wear and distortion. Check fit of fork shoes in synchronizer sleeve to ensure parts fit and work smoothly, replace if necessary. If shift fork pads (2) are worn, the shift fork must be replaced.

Housing/Tail housing: Inspect sealing and mating surfaces are free of burrs and nicks. Inspect alignment dowels are tight and in good condition.

Input Shaft Retainer: Inspect retainer (1) release bearing slide surface (2).

1. Place mainshaft in Fixture 9648 mounted in a vise. 2. Install second gear bearing (1) on mainshaft (2).

3. Install second gear (1) and bearing (2) on mainshaft.

4. Install inner synchronizer friction ring (1) on second gear (2).

5. Install outer synchronizer friction ring (1) on second gear (2).

6. Install synchronizer blocker ring (1) on second gear (2).

7. Install 1-2 synchronizer hub (1) with Installer 8228 (2) and a press. Align hub detent openings with synchronizer rings.

8. Install 1-2 synchronizer hub (1) snap ring (2).

NOTE: Reuse original snap ring or thickest ring that will fit.

9. Install 1-2 synchronizer sleeve (1) and push to the bottom of the synchronizer hub (2).

10. Install 1-2 synchronizer hub (1) detents, springs, and balls (2).

11. Install first gear blocker ring (1) into synchronizer hub (2).

12. Install first gear outer friction ring (1) into synchronizer hub (2).

13. Install first gear inner friction ring (1) into synchronizer hub (2).

14. Install first gear (1) and bearing (2). Then center 1-2 synchronizer sleeve on synchronizer hub.

WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: A bearing heater is used to assemble first gear thrust washer (1) and reverse gear bearing race (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to

follow these instructions will result in component damage.

15. Heat first gear thrust washer (1) and reverse gear bearing race (2) with bearing heater to maximum of 177 Celsius (350° Fahrenheit).

16. Using welding gloves or tongs, install first gear thrust washer (1) then reverse gear bearing race (2).

17. Install reverse gear (1) and bearing (2).

18. Install reverse gear (1) synchronizer friction ring (2).

19. Install reverse gear synchronizer hub (1) on mainshaft with Installer W-262 (2) and a press. Align hub detent opening (3) with friction ring (4) lugs.

20. Install reverse gear synchronizer hub (1) detents (2).

21. Install reverse gear (1) synchronizer sleeve (2) with tooth points pointing down and center sleeve on synchronizer hub. 22. Remove mainshaft from Fixture 9648. Turn fixture over in the vise, then install opposite end of mainshaft in the fixture.

23. Install sixth gear (1) and bearing (2) on mainshaft.

24. Install sixth gear synchronizer blocker ring (1) on sixth gear (2).

25. Install sixth gear synchronizer friction ring (1) on sixth gear (2).

26. Install 5-6 synchronizer hub (1) with Installer W-262 (2) and a press. Align hub detent opening (3) with friction ring lugs (4).

NOTE: 5-6 synchronizer hub center, is offset and must be install with larger offset down.

27. Install 5-6 synchronizer hub (1) snap ring (2).

NOTE: Reuse original snap ring or thickest ring that will fit.

28. Install 5-6 synchronizer sleeve on hub (1).

1. Install countershaft bearing into rear housing with Installer 9643 (1) and Handle C-4171 (2).

2. Install mainshaft bearing (1) into housing (2). 3. Install bearing retainer and tighten bolts to 10 N.m (7.3 ft. lbs.).

4. Install reverse idler gear (1) into housing (2).

5. Install idler gear (1) bearing (2) into gear.

6. Install idler gear (1) thrust washer (2) on idler gear.

7. Install idler gear (1) shaft support (2) into housing.

8. Install idler gear (1) shaft (2) with shaft bolt hole aligned with shaft support hole (3).

9. Install idler gear shaft bolt (1) into the housing (2) and tighten to 20 N.m (15 ft. lbs.).

10. Install 4x4 output shaft seal into rear housing (1) with Installer 9638 (2). Install 4x2 output shaft seal into rear housing with Installer 9635 and Installer 6448A.

1. Install input shaft bearing (1) on input shaft with the bearing retainer lip (2) facing fifth gear.

2. Install input shaft bearing (1) with Installer 6448A (2) and a press.

3. Install input shaft bearing (1) snap ring (2).

NOTE: Reuse original snap ring or thickest ring that will fit.

1. Install input shaft seal with Installer 9635 (1) Installer 6448A (2).

2. Install input shaft (1) with bearing (2) into housing.

3. Install input shaft (1) bearing retainers (2, 3) and tighten bolts to 10 N.m (88 in. lbs.).

4. Install input shaft retainer (1) and tighten bolts (2) to 9 N.m (80 in. lbs.).

5. Install countershaft bearing (1) into housing with bearing retainer lip (2) facing up.

6. Install countershaft bearing (1) retainers (2) and tighten bolts to 10 N.m (88 in. lbs.).

1. Install mainshaft (1) onto Build Fixture 9633 (2).

2. Install countershaft (1) onto Build Fixture 9633 (2).

3. Install oil slinger (3) on countershaft (2) between reverse (1) and first gear (4).

CAUTION: Oil slinger is fragile and can crack during installation. Failure to follow these instructions will result in cracking the oil slinger and lack of oil to first/reverse bearing.

4. Install shift rails and forks (1) onto Build Fixture 9633 (2) and countershaft/mainshaft.

5. Install rear housing on mainshaft (1) with Installer 9636 (2).

6. Remove rear housing with mainshaft, countershaft and shift rails from fixture. Set assembly on rear housing with shafts pointing up. 7. Install 5-6 synchronizer hub (1) detents, springs, and balls (2).

8. Install fifth gear synchronizer friction ring (1) on 5-6 synchronizer hub (2).

9. Install fifth gear blocker ring (1) on 5-6 synchronizer hub (2). Then hold blocker ring and center synchronizer sleeve.

10. Install input shaft roller bearing (1) on mainshaft (2).

11. Install shift rail (1) support plate (2) bolts and tighten to 8 N.m (71 in. lbs.).

12. Apply MOPAR® Gasket Maker to front housing. 13. Install front housing (1) on rear housing (2) and tighten bolts to 28 N.m (21 ft. lbs.).

14. Install output shaft (1) snap ring (2) 4x4 only.

15. Install output shaft (1) seal (2) in rear housing with Installer 9638.

16. Through the shift tower opening (1) move two shift rails (2) forward to lock the transmission in two gear.

17. Install countershaft bolt (1) into the front housing (2) and tighten to 100 N.m (74 ft. lbs.).

18. Install countershaft plug (1) in front housing (2) with Installer 7829-A and Handle C-4171.

19. Move shift rails to neutral. 20. To prevent sealant from plugging the transmission vent, apply just a thin film of MOPAR® Gasket Maker to the shift tower (1) mating surface. 21. Install shift tower (1) and tighten bolts (2) to 14 N.m (10 ft. lbs.).

22. Install back up lamp switch (1) and bolt (2).

1. Install transmission on engine. 2. On 3.7L engine tighten bolts (1) to 41 N.m (30 ft. lbs.). Tighten bolts (2) to 67 N.m (50 ft. lbs.). Tighten bolts (3) to 54 N.m (40 ft. lbs.).

3. On 2.8L diesel engine tighten bolts (1) to 41 N.m (30 ft. lbs.). Tighten bolts (2) to 67 N.m (50 ft. lbs.). Tighten bolts (3) to 54 N.m (40 ft. lbs.).

4. Vehicles with 3.7L engine install exhaust pipe with converters (3).

5. Install transmission crossmember (2) and tighten bolts to 47 N.m (35 ft. lbs.). Install transmission mount (1) bolts and tighten to 47 N.m (35 ft. lbs.).

6. Install backup lamp (2) wiring connector (1).

7. Install clutch slave cylinder (2) and mounting nuts (1).

8. Install transfer case (1) on transmission (2), if equipped. 9. Install propeller shaft/shafts with reference marks aligned.

10. Remove fill plug (1) and fill transmission to specifications.

11. Install inner shift boot (3), shift lever (2) and lever screw (1).

12. Install shift boot (2), shift knob (1) and console. 13. Connect battery.

Input Shaft Retainer 9 - 80 Bolts

Transmission Mount to 47 35 - Transmission Bolts Transmission Top Four 40 30 - Bolts Transmission Side Two 68 50 - Bolts Transmission Bottom 54 40 - Four Bolts 2WD Transmission 175 130 - Damper Bolts

REVERSE 4.06