Chrysler Full-Size Trucks 1989-1996 Repair Guide

Shifter Handle

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REMOVAL & INSTALLATION



Overdrive-4

See Figure 1

This procedure covers the shift linkage as well as the handle removal and installation.

  1. Disconnect the negative battery ground cable.
  2.  
  3. Remove the shift boot retaining screws and slide the boot up the shift lever.
  4.  



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Fig. Fig. 1: Remove the hand lever as shown from the Overdrive-4 transmission

  1. Remove the shift lever by inserting a 0.010 in. (0.25mm) feeler gauge blade down the left (driver's) side of the shift lever mounting socket (just above the linkage pivot shift unit) to depress the pin detents that secure the lever.
  2.  
  3. Remove the retaining clips, washers and control rods from the shift unit levers.
  4.  
  5. Remove the two bolts and washers that secure the shift unit to the side of the extension and remove the unit.
  6.  
  7. Service as required. Fasten the shift unit to the side of the extension housing and secure it with the two mounting bolts and washers. Tighten the mounting bolts to 30 ft. lbs. (41 Nm).
  8.  
  9. Install the shift rods, washers and clips.
  10.  
  11. Install the shift lever and secure the shifter boot.
  12.  

NP2500

The gearshift lever is a two-piece design. The upper part of the lever is threaded to the transmission stub lever. The upper lever can be removed for service without having to remove the entire shift lever assembly or the transmission. If the upper lever must be serviced, remove the boot mounting screws, the support and trim bezel for access to the lower end of the shifter. Un-thread and remove the upper end of the shift lever. Service as required. Thread the upper lever to the stud end and secure the shift boot and components.

NV3500

See Figure 2

  1. Remove the shift boot bezel screws and slide the boot upward on the shift lever extension.
  2.  
  3. Remove the four bolts attaching the shift tower and lever assembly to the rear case. Then remove the tower and lever extension as an assembly.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Install the shift lever using the special tool as shown-NV3500/NV4500 transmission

To install:
  1. Install the isolator plate on the shift tower, or rear case. Then install the shift tower and lever assembly. Tighten the shift tower bolts 5-7 ft. lbs. (7-10 Nm). Note that the isolator plate is a one-way fit. Narrow side goes toward the driver's side of the transmission.
  2.  
  3. If the shift extension was removed from the shift lever, install the lever extension on the shift lever with tool No. 6783 as follows:
    1. Reposition the upper jaw of the Remover/Installer Tool No. 6783 ABOVE the flange on the shift lever extension. The tool will now be used to press the extension back onto the shift lever.
    2.  
    3. Tighten the tool screw to press the extension back onto the lever. Press the extension to scribe the mark made during the removal. A 0.12-0.20 in. (3-5mm) space should exist between the shift lever isolator and the top edge of the stub shaft and tool upper jaw.
    4.  
    5. Remove the special tool.
    6.  
    7. Install the shift lever boot and bezel.
    8.  

  4.  

NV4500

See Figures 2, 3 and 4

This procedure is for removal/installation with the transmission IN the vehicle.



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Fig. Fig. 3: Use the special factory tool to remove the shift lever as shown-NV4500 transmission



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Fig. Fig. 4: Details of the shift lever-NV4500 transmission

  1. Remove the shift lever boot, then remove the shift lever extension with the Remover/Installer Tool No. 6783 as follows:
    1. Position the notched, lower end of the tool just under the square shank of the shift lever.
    2.  
    3. Position the tool upper jaws UNDER the flange on the shift extension.
    4.  
    5. Tighten the tool screw to pull the extension off the square shank of the shift lever.
    6.  
    7. Remove the lever extension and tool.
    8.  

  2.  

To install:
  1. Install the lever extension on the shift lever with tool No. 6783 as follows:
    1. Reposition the upper jaw of the Remover/Installer Tool No. 6783 ABOVE the flange on the shift lever extension. The tool will now be used to press the extension back onto the shift lever.
    2.  
    3. Tighten the tool screw to press the extension back onto the lever. Press the extension to scribe the mark made during the removal. A 0.12-0.20 in. (3-5mm) space should exist between the shift lever isolator and the top edge of the stub shaft and tool upper jaw.
    4.  
    5. Remove the special tool.
    6.  
    7. Install the shift lever boot and bezel.
    8.  

  2.  

 
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