Jeep Wrangler NV3550 manual gearbox factory workshop and repair manual
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The NV3550 is a medium-duty, 5-speed, constant mesh, fully synchronized manual transmission. The transmission is available in two and four-wheel drive configurations.
TABLE OF CONTENTS
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
SPECIFICATIONS
SPECIAL TOOLS
EXTENSION HOUSING BUSHING
REMOVAL
INSTALLATION
EXTENSION HOUSING SEAL
REMOVAL
INSTALLATION
Jeep Wrangler NV3550 manual gearbox factory workshop and repair manual
- Quick correction and what that means for the job
- The NV3550 manual gearbox does NOT have a camshaft position sensor. Camshaft (and crankshaft) position sensors are engine sensors mounted on the cylinder head or bellhousing area of the engine, not on the transmission.
- The NV3550 gearbox commonly has an output/vehicle speed sensor (VSS) and gear/neutral/reverse switches. If you intended to work on a sensor at the NV3550, you almost certainly mean the vehicle speed sensor (output speed sensor) or the neutral/reverse switch — the guide below covers the VSS (most common replacement) and notes about the engine camshaft sensor if you actually meant the engine.
- Safety first
- Wear safety glasses and gloves to protect eyes and hands.
- Use wheel chocks and jack stands — do not rely on a jack alone.
- Work on a flat, level surface and keep a drain pan for any fluid drips.
- Tools (detailed descriptions and how to use each)
- Ratchet (3/8" drive recommended)
- Description: Hand tool with a reversible mechanism to turn sockets quickly.
- How to use: Fit the correct socket onto the square drive, set the direction lever, and pull/push the handle to loosen/tighten fasteners.
- Metric socket set (commonly 8mm, 10mm, 13mm)
- Description: Collection of sockets sized for metric bolts/nuts.
- How to use: Choose the socket that fits snugly on the bolt head; use with the ratchet and an extension if the bolt is recessed.
- Socket extension(s)
- Description: Short metal bars that extend reach of the ratchet.
- How to use: Insert extension between ratchet and socket to reach sensors tucked into the tailhousing.
- Combination wrenches (metric set, same sizes as sockets)
- Description: Open and boxed-end wrenches for places a ratchet can’t reach.
- How to use: Box end for best grip on nut; open end for quick access in tight spots.
- Flathead screwdriver
- Description: Straight-blade screwdriver.
- How to use: Pry plastic clips, release connector tangs, or leverage stuck connectors gently.
- Penetrating oil (PB Blaster or Liquid Wrench)
- Description: Lubricant that loosens rusted/ seized fasteners.
- How to use: Spray on bolt threads, wait 10–15 minutes, then attempt removal.
- Multimeter (digital)
- Description: Measures voltage, resistance, and sometimes frequency/AC.
- How to use: Set to DC volts or resistance to test wiring and basic sensor outputs; follow the step instructions below.
- Electrical contact cleaner
- Description: Cleaner to remove corrosion/grease from connectors.
- How to use: Spray into electrical connectors after unplugging; allow to dry before reconnecting.
- Small wire brush or pick
- Description: Clean corrosion from connector pins or sensor seat.
- How to use: Gently clean contacts and sensor mating surface.
- Small flashlight or work light
- Description: Illuminates dark areas under vehicle.
- How to use: Position to give clear light into the bellhousing/tailshaft area.
- Jack and jack stands
- Description: Hydraulic jack to lift vehicle and stands to safely hold it up.
- How to use: Lift vehicle with the jack only to place jack stands under recommended lift points, lower onto stands, then remove jack.
- Wheel chocks
- Description: Blocks to stop wheels from rolling.
- How to use: Place behind and in front of wheels left on the ground.
- Replacement sensor (see parts section)
- Description: New vehicle speed sensor (VSS) or the correct engine cam sensor if replacing engine part.
- How to use: Install in reverse order of removal; use new O-ring/seal if included.
- Optional but recommended: impact driver or air ratchet, torque wrench
- Why optional: Impact speeds removal of seized fasteners; torque wrench ensures proper final tightness for sensor bolts.
- What you’ll likely be replacing and why
- Vehicle speed sensor (VSS) — why replace
- Symptoms: Speedometer not working, erratic speed reading, transmission shift problems (on automatics) or ABS/traction anomalies, or warning lights related to speed input.
- Reason: Sensor failure due to corrosion, wiring damage, internal electronics failure, or a damaged O-ring/gear causing leaks.
- Neutral/reverse switches — why replace
- Symptoms: Reverse lights not working or neutral switch related indicators.
- Reason: Failed switch or corroded connector.
- Camshaft position sensor (engine) — if that’s actually what you meant
- Symptoms: Hard starting, poor idle, misfires, engine warning lamp.
- Reason: Engine sensor failure or wiring damage.
- How to inspect and test the VSS (basic checks for a beginner)
- Visual inspection first
- Look for damaged wiring, corroded connector, or fluid leak at sensor.
- Clean connector with electrical cleaner and re-seat; check if problem temporarily resolves.
- Basic multimeter check (beginner-friendly)
- With key ON (engine off), backprobe the sensor connector signal pin and ground.
- If VSS is an active (Hall-effect) sensor, you may see ~5V reference on one pin; signal will vary when the shaft is spun. If unsure, just check for continuity to ground and for obvious open circuits.
- If you can safely spin the output shaft (with wheel removed and vehicle secured) and see pulsing voltage, the sensor is producing a signal.
- If you are unsure how to identify wires, skip electrical tests and move to replacement if symptoms and visual damage are clear.
- Removing and replacing the NV3550 vehicle speed sensor (step-by-step for a beginner)
- Prepare vehicle
- Chock wheels, set parking brake, raise vehicle with jack and secure on stands, verify stable.
- Locate the sensor
- Find the tailhousing of the NV3550 (rear of transmission where the output shaft is). The VSS is typically threaded into the tailhousing with a single bolt or is threaded directly into the tail housing.
- Use a flashlight; the sensor will have a wiring harness plugged into it.
- Disconnect electrical connector
- Depress the tab on the connector and pull straight off; use flathead screwdriver to release stubborn tabs if needed.
- Remove sensor fastener(s)
- Use the correct socket or wrench on the retaining bolt. Apply penetrating oil and wait if stubborn.
- Turn counterclockwise to loosen; use extension if recessed.
- Remove the sensor
- Pull straight out; wiggle gently if stuck. Note any O-ring or metal sleeve — keep or replace.
- Clean mating bore with rag; use small brush if needed but avoid pushing debris into gearbox.
- Install new sensor
- Compare new sensor to old for matching length and connector style.
- Lubricate new O-ring lightly with gear oil (if O-ring type). Insert sensor straight, then secure bolt to snug. If you have a torque wrench, torque to manufacturer spec (typically low torque for sensor bolt; if you don’t have a spec, snug it firmly without over-torquing).
- Reconnect electrical connector until it clicks.
- Test before reassembly
- Lower vehicle enough to spin wheel or drive briefly to check speedometer operation, or turn ignition on and check for signal with multimeter.
- Clean up
- Check for leaks, remove tools, lower vehicle from stands.
- If the camshaft position sensor (engine) is what you actually want
- General notes for a Wrangler TJ / similar Jeep engines
- Cam sensor location depends on engine year/type (e.g., 4.0L cam sensor on cylinder head near timing cover). Sensor is usually 1–2 bolts, with a single electrical connector.
- Tools: same basic hand tools, plus maybe a small socket/extension set and a ratchet; engine-specific access may require removing intake or airbox with a set of pliers/ratchet.
- Replacement: unplug connector, remove mounting bolt(s), replace sensor and reattach connector. Test by starting engine and checking for reduced symptoms or clearing codes.
- When replacement is required and what to buy
- Replace the sensor when:
- Visual damage/corrosion is present.
- Connector wiring is melted, cut, or corroded.
- Diagnostic checks show no signal or intermittent signal.
- Cleaning and reseating connectors do not restore proper operation.
- What to buy for NV3550 tailhousing
- Vehicle speed sensor (VSS) specific to Jeep model year and NV3550 gearbox — buy OEM Mopar part or a known aftermarket equivalent that lists fitment for your year/make/model and NV3550.
- Replace O-ring or seal if included with sensor — always use the new one.
- What to buy for camshaft sensor (engine)
- Camshaft position sensor listed for the specific engine code/year of your Wrangler; OE or quality aftermarket unit.
- Where to confirm fitment
- Use the vehicle VIN or engine code on parts sites or consult a dealer parts counter to confirm the exact sensor part number.
- Additional tips for a complete beginner (no nonsense)
- If connector is corroded, cleaning it often fixes an intermittent problem — try that first.
- Keep hardware and old sensor until you’ve verified the new sensor works.
- Take photos before unplugging connectors so you can reconnect correctly.
- If bolts are heavily corroded or rounded, you may need an extractor set or penetrating oil plus patience.
- If you do not feel comfortable under the vehicle or near moving parts, consider a shop to avoid injury.
- Final practical summary (what you will likely need to do)
- If you meant NV3550 gearbox sensor: inspect wiring/connector, test signal if possible, replace the VSS (common fix).
- If you actually meant camshaft position sensor on the engine: remove engine intake/accessory as needed, unplug and swap sensor, verify operation.
- Tools: basic metric socket/ratchet set, extension, screwdriver, penetrating oil, multimeter, jack stands, contact cleaner. Optional: torque wrench, impact tools, extractor set.
- Parts recommendation (generic)
- Buy the specific VSS for NV3550 for your Wrangler year — OEM Mopar or quality aftermarket brand (Dorman, Standard Motor Products, NTK). Ensure the listing specifies NV3550 or your Jeep year/model/engine.
- For an engine cam sensor, buy the sensor specifying your engine code/year; OEM or reputable aftermarket brands.
- Troubleshooting if replacement does not fix it
- Check wiring continuity and grounds from the sensor connector to the ECU/cluster.
- Check the instrument cluster or ECU codes — sensor replacement won’t help if cluster or wiring is bad.
- If electrical testing is beyond comfort, take the car to a shop with your new sensor and the old one for a quick bench test/diagnosis.
No extra questions. rteeqp73
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