NV1500 rebuild tips?

[bonhommechristopher]

Hey all, I own an '03 liberty sport, manual transmission, 4 cylinder motor. Last fall my clutch locked up on me right as I was pulling into my driveway. Some buddies and I pulled the ****** to install a new clutch (230,000 on the original clutch :sparta: ) and we found out the the input bearing on the ****** was so worn that it was allowing about a quarter of an inch of play in the input shaft and consequently the clutch friction plate had turned sideways slightly and gotten stuck. I am going to get a rebuild kit with new bearings, seals, and synchros and rebuild the thing. I miss my girl and I want her back asap. I found an nv1500 full manual online, and several companies that make the kit. Do any of you have experience doing this and are there any recommended brands or special tips and tricks that I should know about? Thanks! :boxing:

 

[Dave]

Bumped this up for you hoping someone that can help will see it.

Dave

 

[bonhommechristopher]

NV1500 NV2550 TRANSMISSION REBUILD KIT WITH SYNCHRO RINGS FITS '00-'04 JEEP WRANGLER, LIBERTY & DODGE DAKOTA (BK494WS - The American Powertrain Warehouse

This is the rebuild kit I am going with. I also ordered a new set of needle bearings. I will update this post as the project progresses.

 

[bonhommechristopher]

Well, I tore the transmission apart today. It's super simple really. There are only two main shaft bearings, and as I suspected they were worn just enough to allow endplay in the shaft. That's what had locked my clutch up. For future reference, everything on the ****** is standard, but the shift rod lock allen head is metric, and one of the bolts on the side holding an idler gear (?) is 15mm. all of the case bolts are 1/2". In order to split the cases you have to remove the shift rod lock bolt on the top of the forward half of the case. You will also have to remove the cap, spring, and pin that locks in the detents of the shifter rod to the rear. remove the idler gear on the lower left side by taking out the two bolts on the outside of the case. The transmission has to be in neutral to remove the gear and shift fork assemblies. once in neutral, turn the shifter all the way to the right so that it can slide under the case. remove the shaft retainer by taking out the three bolts on the back of the case. Everything slides out easily. On to cleaning all the parts and cases and then installing the rebuild kit!

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