Manual Transmission Pops Out of Gear – 2007-2010 Jeep

NUMBER: 21-001-10 REV. A
GROUP: Transmission
DATE: April 20, 2010

 

SUBJECT:

Manual Transmission Pops Out of Gear

 

OVERVIEW:

This bulletin involves verifying that the transmission shift boot is not interfering with the engagement of first gear and if not than, replace the first gear and 1-2 synchronizer assembly.

 

MODELS:

2007 – 2010	KA/KK	Nitro/Liberty
2007 – 2010	JK	Wrangler

 

NOTE: This bulletin applies to vehicles equipped with a manual transmission (sales code DEH).

 

SYMPTOM/CONDITION:

The transmission pops out of first gear while accelerating. The condition, may occur intermittently and may be difficult to diagnose.

 

DIAGNOSIS:

Verify that the shift boot is not causing the issue by ensuring the boot is not binding when in first gear. In addition, if the customer complains that the transmission pops out of gear in first, third, and fifth, than the shift boot would be most likely the cause for the complaint. Refer to the appropriate service information regarding shift boot replacement. If the shift boot is not causing the transmission to pop out of first gear, perform the following Repair Procedure.

 

PARTS REQUIRED:

Qty.	Part No.	Description
1	68080512AB	Kit, First Gear and 1-2 Synchronizer Assembly – INTERNATIONAL ONLY
1	68085902AA	Kit, First Gear and 1-2 Synchronizer Assembly – NAFTA/LATIN AMERICA ONLY
2	04874464	Lubricant, Manual Transmission
AR (1)	04318083	Gasket Maker

 

SPECIAL TOOLS/EQUIPMENT REQUIRED:

9633	NSG370 Manual Transmission Build Fixture
9636	Mainshaft/Bearing Remover
9648	Mainshaft Build Fixture
8228	1-2 Synchronizer Hub Installer
W-262	Reverse Gear Synchronizer Hub Installer
	Standard Three Jaw Gear Puller
	Bearing Heater/Hot Plate

 

REPAIR PROCEDURE:

1. Remove the transmission from the vehicle. Follow the procedures identified in DealerCONNECT>TechCONNECT>Service Info>21 – Transmission and Transfer Case>Manual, NSG370>Disassembly>Disassembly.
2. Disassemble the transmission. Follow the procedures identified in DealerCONNECT>TechCONNECT>Service Info>21 – Transmission and Transfer Case>Manual, NSG370>Disassembly>Disassembly.
3. Install the new first gear and the 1-2 synchronizer assembly (from kit p/n 68080512AB – INTERNATIONAL ONLY or p/n 68085902AA – NAFTA/LATIN AMERICA ONLY) onto the mainshaft. Follow the procedures identified in DealerCONNECT>TechCONNECT>Service Info>21 – Transmission and Transfer Case>Manual, NSG370>Assembly>Assembly.

NOTE: When installing the synchronizer sleeve, make sure that the side of the sleeve with the groove faces toward second gear.

NOTE: The selective snap rings are made available in case the mainshaft snap ring is damaged when disassembling the shaft. Upon reassembly, select the thickest snap ring that will fit properly in the snap ring groove.

4. Then, reassemble the transmission using the new front countershaft seal and output shaft seal (from kit p/n 68080512AB – INTERNATIONAL ONLY or p/n 68085902AA NAFTA/LATIN AMERICA ONLY).
5. Install the transmission into the vehicle. Follow the procedures identified in DealerCONNECT>TechCONNECT>Service Info>21 – Transmission and Transfer Case>Manual, NSG370>Installation>Installation.
6. Fill the transmission with 1.5 L (3.17 pts.) of Mopar Manual Transmission Lubricant (p/n 04874464).

 

POLICY:

Reimbursable within the provisions of the warranty.

 

TIME ALLOWANCE:

Labor Operation No:	Description	Amount
21-00-11-90	Transmission, Install 1-2 Synchronizer Assembly – 4X4 Only (B).	5.4 Hrs.
21-00-11-92	Transmission, Install 1-2 Synchronizer Assembly – 4X2 Only (B).	4.2 Hrs.

 

FAILURE CODE:

ZZ	Service Action

 

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. PARTS ARE NOT EXPECTED TO BE AVAILABLE UNTIL APRIL 23, 2010. UNLESS THERE IS AN IMMEDIATE NEED, DO NOT ORDER PARTS UNTIL APRIL 23, 2010. ALL ORDERS WILL BE HELD UNTIL STOCK IS ON HAND.

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-001-10, DATED MARCH 2, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PART NUMBERS FOR THE FIRST GEAR AND 1-2 SYNCHRONIZER KIT AND A REVISION TO THE 4X2 LABOR OPERATION NUMBER.