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TSB 21-005-01

Partial Engagement Of First And/Or Second Gear

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Date: Mar. 02, 2001

Models: 2000 (BR/BE) Ram Truck with NV3500 5-speed

2000    AN Dakota
2000    BR/BE Ram Truck
2000    TJ Wrangler
2000    XJ Cherokee

NOTE: THIS BULLETIN APPLIES TO WRANGLER OR CHEROKEE VEHICLES EQUIPPED WITH A NV3550 MANUAL TRANSMISSION, AND TO DAKOTA OR RAM TRUCK VEHICLES EQUIPPED WITH A NV3500 MANUAL TRANSMISSION THAT WERE BUILT ON OR BETWEEN NOVEMBER 20,1999 (MDHI 12OXX) AND MAY 17, 2000 (MDH0517XX).

Discussion:
This bulletin involves replacement of the shift shaft lever to allow the addition of a new detent spring and plunger.

Symptom/Condition:
The customer may complain that first or second gear may not stay fully engaged. This condition may often occur once the gear has been selected and as the clutch is initially released. This condition may be intermittent in its occurrence.

Diagnosis: 

1. Verify that full motion of the shift lever is allowed by the gear shift lever boot, the inner gear shift boot, and the console. The boots or console may be out of place and/or position.

2. If full motion of the transmission shift lever has been verified, and the customer has complained of the above condition, then perform the Repair Procedure.

NOTE: SEVERAL ITEMS MAY CAUSE A SIMILAR CONDITION, BUT REQUIRE TRANSMISSION DISASSEMBLY TO DIAGNOSE. THE TECHNICIAN SHOULD INSPECT THE DISASSEMBLED TRANSMISSION FOR BROKEN TOOTH POINTS, A BENT OR FRACTURED SHIFT FORK, OR FOR PARTS WHICH HAVE FAILED DUE LACK OF LUBRICATION. THE REPAIR PROCEDURE FOR THIS TSB INVOLVES ONLY THE REPLACEMENT OF THE SHIFT SHAFT LEVER AND THE INSTALLATION OF THE DETENT SPRING AND PLUNGER.

Parts Required:

Qty.	Part No.	Description
1	05072248AA	Lever, Shift Shaft
1	05013348AA	Plunger, Shift Shaft Lever Detent
1	04741137	Spring, Shift Shaft Lever Detent
1	04741138	Pin, Shift Shaft Lever Roll
1	04741118	Seal, Rear (4wd Only)
3	04874464	Fluid, Transmission (MS-9224 / Qt.1)
1	04318083	Mopar Gasket Maker

Equipment Required:

6747	Fixture
6858	Remover / Installer
C-3860-A	Installer
8115	Cup
6747-1 A	Adapter
6747-2B	Adapter

Repair Procedure: 

1. Using the appropriate year Service Manual, Group 21 - Transmissions, remove and disassemble the transmission to the point where the front transmission housing has been removed.

2. Remove the old shift shaft lever.

3. Install the revised shift shaft lever p/n 05072248AA.

4. Verify that the notches in the shift fork arms are aligned.

5. Rotate the shift shaft lever and bushing downward (out of the fork arms), to expose the detent bore in the new shift shaft lever (Fig. 1).

 

Fig. 1 SHIFT SHAFT LEVER 1 - SHIFT FORK ARMS IN ALIGNMENT 2 - SHIFT SHAFT LEVER DETENT BORE EXPOSED

6. Lubricate the detent spring, detent plunger, and detent bore with transmission fluid, p/n 04874464.

7. Install the detent spring, p/n 04741137, into the shift shaft lever detent bore.

8. Install the detent plunger, p/n 05013348AA, on top of the detent spring and compress both parts into the bore (Fig. 2).

 

Fig. 2 DETENT AND SPRING 1 - SHIFT SHAFT LEVER 2 - DETENT PLUNGER AND SPRING 3 - MAGNET TO ASSIST WITH ASSEMBLY

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Notes: 

Policy:    Information Only

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Labor Operation No:
21-75-01-90	Plunger, Detent - Replace (TJ, XJ)	0.4 Hrs.
21-75-01-90	Plunger, Detent - Replace (AN, BR, BE)	0.6 H rs.

Failure Code:

P8

New Part

This page was edited on: May 3, 2004