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G56
Service Manual
68 pgs1.63 Mb0

Dodge G56 Service Manual

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TRANSMISSION AND TRANSFER CASE 21 - 1
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - G56 - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MANUAL TRANSMISSION - GETRAG 238 -
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . 69
MANUAL TRANSMISSION-T56 - SERVICE
AUTOMATIC TRANSMISSION 42RLE -
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 202
AUTOMATIC TRANSMISSION 42RLE - SERVICE
AUTOMATIC TRANSMISSION - 545RFE -
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 579
AUTOMATIC TRANSMISSION - 45RFE/545RFE -
SERVICE INFORMATION . . . . . . . . . . . . . . . . . 842
AUTOMATIC TRANSMISSION - 48RE - GAS -
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 987
AUTOMATIC TRANSMISSION - 48RE - DIESEL -
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . 1105
AUTOMATIC TRANSMISSION - 48RE - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1266
TRANSFER CASE - ELECTRICAL
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 1499
TRANSFER CASE - NV241 GENII - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1563
TRANSFER CASE - NV271 - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1605
TRANSFER CASE - NV243 - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1656
TRANSFER CASE - NV244 GENII - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1700
TRANSFER CASE - NV273 - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1743
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
TABLE OF CONTENTS
MANUAL TRANSMISSION - G56 - SERVICE
INFORMATION
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - G56 . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
DRAIN AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
page page
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ADJUSTMENTS
MAINSHAFT/COUNTERSHAFT BEARING
PRELOAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SPECIFICATIONS
MANUAL TRANSMISSION-G56 . . . . . . . . . . . . . . . 65
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
21 - 2 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
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MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - G56
LOW LUBRICANT LEVEL
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 or overfill condition.
HARD SHIFTING
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.
TRANSMISSION NOISE
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, synchronizer rings, shift rails, forks and bear­ings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.
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MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 3
STANDARD PROCEDURE
DRAIN AND FILL
1. Raise and support vehicle.
2. Remove drain plug (1) on transmission (2) and drain fluid.
3. Install drain plug and tighten to 57 N·m (42 ft. lbs.).
4. Remove fill plug (1) on right side of the transmis­sion (2).
5. Fill transmission even with the bottom of the fill hole.
6. Install fill plug and tighten to 57 N·m (42 ft. lbs.).
21 - 4 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
REMOVAL
1. With vehicle in neutral, position vehicle on hoist.
2. Disconnect battery negative cable.
3. Remove shift boot bezel screws and slide boot upward on shift lever extension.
4. Remove shift lever extension from the shift tower and lever assembly.
5. Remove 4WD shift boot if equipped.
6. Remove skid plate, if equipped.
7. Remove drain plug (1) from transmission (2) and drain fluid.
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8. Mark transmission flange (1) and propeller shaft (2) for installation reference before removing propeller shaft. If 4x4 equipped mark transfer case and front propeller shaft before removing shaft.
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9. Disconnect harness from clips on transmission housing.
10. Remove transfer case linkage 4x4 equipped.
11. Remove transfer case mounting nuts and remove
transfer case 4x4 equipped.
12. Remove slave cylinder (1) mounting nuts (2) and
remove cylinder.
13. Remove starter motor (1) on 5.7L engine.
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 5
21 - 6 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
14. Remove structural dust cover (1) clutch housing
bolts (2) and dust shield bolts (3) on 5.7L engine.
CAUTION: On 5.7L engine do not remove struc­tural dust cover from engine block. If cover is removed clutch housing and structural dust cover must be aligned with the engine.
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15. Remove exhaust bracket (1) bolts and remove
bracket on diesel engine.
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16. Support engine with adjustable jack stand and
wood block.
17. Support and secure transmission (1) to a trans-
mission jack (2) with safety chains.
18. Remove transmission mount bolts (1).
19. Remove rear crossmember bolts (2) and remove
crossmember with transmission mount.
20. Remove exhaust Y-pipe on 5.7L engine.
21. Remove bolts attaching transmission to the
engine.
22. Move transmission rearward until input shaft is
clear of clutch disc and pressure plate. Then lower jack and remove transmission from under vehicle.
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 7
21 - 8 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
DISASSEMBLY
1. Set transmission on rear housing.
2. Remove shift tower bolts (1) and shift tower (2).
3. Pry off shift tower boot (1) with a screw driver (2).
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4. Through the shift tower opening (1) align shift rails (2) and install tie strap to shift rails.
5. Remove 5-6 shift fork pivot pin (1) from both sides of the case.
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 9
6. Remove reverse idler gear shaft pin (1) from the rear housing (2).
21 - 10 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
7. Remove back-up lamp switch (1) bolt (2) and remove switch.
8. Remove transmission housing bolts.
9. Tap housing with dead-blow hammer and lift front housing (1) off rear housing (2).
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10. Remove 5-6 shift fork (1) from shift rail and syn-
chronizer sleeve (2).
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11. Remove input shaft (1) from mainshaft (2).
12. Thread a M6x1bolt (1) into the reverse idler gear
shaft (2) and pull shaft out of rear housing.
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 11
13. Slide reverse idler gear (1) off to the side of the
case (2) for disassembly clearance.
21 - 12 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
14. Lift and tilt countershaft (1) then remove main-
shaft with shift rails (2).
15. Remove countershaft.
16. Remove reverse idler gear (1) from rear housing
(2).
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MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 13
MAINSHAFT
1. Remove reverse (1) 1-2 (2) and 3-4 (3) shift forks and shift rails as an assembly from mainshaft.
2. Position mainshaft in Fixture 9605 mounted in a vise with sixth gear up.
3. Remove fifth gear synchronizer rings (1) from 5-6 synchronizer hub (2).
21 - 14 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
4. Slowly pull 5-6 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).
5. Remove 5-6 synchronizer sleeve (1) from hub (2).
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6. Remove mainshaft bearing (1) snap ring (2).
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7. Remove mainshaft bearing (1), 5-6 synchronizer hub (2), and sixth gear synchronizer rings (3) with three jaw puller (4). Position puller jaws under sixth gear synchronizer rings (3).
8. Remove sixth gear (1) and bearing (2) from main­shaft (3).
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 15
9. Remove fourth gear (1) snap ring (2).
21 - 16 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
10. Remove fourth gear thrust washer (1) with Puller
9594. Position puller under fourth gear synchro­nizer stop ring (2).
11. Install Bridge 938 (1) into Puller 9594 (2) and
remove fourth gear thrust washer (3).
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12. Remove fourth gear (1) and bearing (2).
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13. Remove fourth gear synchronizer rings (1) from
3-4 synchronizer hub (2) and mark installation reference.
14. Slowly pull 3-4 synchronizer sleeve (1) up on hub
enough to remove detents and springs (2).
15. Remove 3-4 synchronizer sleeve (1) from hub.
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 17
16. Remove 3-4 synchronizer hub (1) snap ring (2).
21 - 18 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
17. Remove 3-4 synchronizer hub (1) and third gear
synchronizer rings (2). Mark components for installation reference.
18. Remove third gear (1) and bearing (2).
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19. Turn mainshaft and Fixture 9605 and secured in
vise.
20. Remove 4x4 mainshaft snap ring.
21. Remove reverse gear synchronizer sleeve (1)
from reverse gear (2) synchronizer hub.
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22. Remove reverse gear synchronizer hub (1)
detents (2).
23. Remove mainshaft bearing (1) with Bridge 938 (2)
and bearing Puller 9647 (3).
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 19
24. Position puller (1) behind reverse synchronizer
hub and outer blocker ring (2).
21 - 20 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
25. Remove reverse gear (1) and bearing (2).
26. Remove reverse gear bearing race (1) and thrust
washer (2). Use Puller 9646 and Bridge 938 on first gear (3) to pull off reverse gear bearing race (1) and thrust washer (2).
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27. Remove first gear (1) and bearing (2).
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28. Remove first gear synchronizer rings (1) from 1-2
synchronizer hub (2) and mark for installation reference.
29. Slowly pull 1-2 synchronizer sleeve (1) up on hub
(2) enough to remove detents and springs (3).
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 21
30. Remove 1-2 synchronizer hub (1) snap ring (2)
and remove hub with second gear synchronizer rings. Mark components for installation reference.
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