DODGE RAM 1500 1998 2.G Workshop Manual

(6) Drive out shift bushing and lever roll pin with
a hammer and punch (Fig. 17).
NOTE: Use proper size punch to avoid bending the
shift shaft.
(7) Pull shift shaft straight out of rear housing,
shift socket, fifth-reverse fork and 1-2 fork (Fig. 18).
(8) Remove shift socket from rear housing (Fig.
19).
(9) Remove shaft lever and bushing (Fig. 20).
(10) Rotate 3-4 fork around synchro sleeve until
fork clears shift arms on 1-2 and fifth-reverse forks,
then remove 3-4 fork (Fig. 21).
Fig. 17 SHIFT SHAFT LEVER & BUSHING ROLL PIN
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 18 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 19 SHIFT SOCKET & ROLL PIN
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 20 SHIFT SHAFT LEVER & BUSHING
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 21 3-4 SHIFT FORK
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
21 - 8 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(11) Remove reverse idler shaft support bolt and
loosen rear reverse idler shaft bolt (Fig. 22).
(12) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(13) Support geartrain and rear housing on Fix-
ture 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2A on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 23).
(d) Stand geartrain and rear housing upright on
fixture (Fig. 24). Have helper hold fixture tool in
place while housing and geartrain is being rotated
into upright position.(14) Remove rear bolt holding reverse idler shaft
in housing.
Fig. 22 REVERSE IDLER SHAFT & SUPPORT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 23 FIXTURE ASSEMBLY
1 - FIXTURE 6747
2 - ADAPTER 6747-1A
3 - CUP ADAPTER 8115
4 - REVERSE IDLER PEDESTAL
5 - ADAPTER 6747-2A
Fig. 24 GEARTRAIN & HOUSING ON FIXTURE
1 - INPUT SHAFT
2 - COUNTERSHAFT
3 - FIXTURE 6747
DRMANUAL TRANSMISSION - NV3500 21 - 9
MANUAL TRANSMISSION - NV3500 (Continued)

REAR HOUSING - 2WD
(1) On 2-wheel drive transmission, remove three
bolts that attach output shaft bearing retainer to
rear case (Fig. 25). Bolts are rear of shift tower open-
ing.
(2) Tap rear housing upward and off output shaft
bearing with a plastic/rawhide hammer (Fig. 26).
(3) Lift rear housing up and off geartrain (Fig. 27).
Fig. 26 SEPARATE REAR HOUSING & OUTPUT
SHAFT BEARING
1 - REAR HOUSING
2 - MALLET
3 - FIXTURE
Fig. 27 REAR HOUSING - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 25 OUTPUT SHAFT
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
21 - 10 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(4) Remove countershaft rear bearing from coun-
tershaft (Fig. 28).
REAR ADAPTER HOUSING - 4WD
(1) Inserting screw from slide hammer (Fig. 29)
into one of the dimples in face of rear seal (Fig. 30)
and remove seal.
(2) Remove rear bearing snap ring from output
shaft (Fig. 31).
(3) Lift rear adapter housing upward and off
geartrain (Fig. 32).
(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 33). Push or
tap bearing out of housing with a hammer handle if
needed.
Fig. 28 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - OUTPUT SHAFT
3 - COUNTER SHAFT
Fig. 29 REAR SEAL
1 - SLIDE HAMMER
2 - REMOVER TOOL
3 - REAR SEAL
Fig. 30 REAR SEAL FACE
1 - DIMPLES
2 - SEAL FACE
Fig. 31 REAR BEARING SNAP RING
1 - HEAVY DUTY SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 32 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
DRMANUAL TRANSMISSION - NV3500 21 - 11
MANUAL TRANSMISSION - NV3500 (Continued)

NOTE: Housing must be replaced if race, bearing
bore or idler shaft notch are worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove reverse idler gear assembly from
assembly fixture cup.
(2) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(3) Slide countershaft out of fixture tool.
(4) Remove output shaft bearing retainer from
rear surface of fifth gear (retainer will drop onto gear
after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from the fixture.
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different
and must not be mixed. Remove each synchronizer
unit as an assembly to avoid mixing parts. Mark
each synchro hub and sleeve with a scriber or paint
for correct assembly reference.(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Position Bearing Splitter 1130 between second
and third gears and press off 3-4 synchro assembly,
third gear synchro ring and third gear with a shop
press.
(3) Remove third gear needle bearing (Fig. 34).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft with a small pry tool (Fig.
35).
Fig. 33 REAR ADAPTER HOUSING COMPONENTS
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 34 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 35 THRUST WASHER
1-PRYTOOL
2 - THRUST WASHER RETAINING RING
21 - 12 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(5) Remove two-piece thrust washer (Fig. 36) and
note position of washer locating lugs in shaft notches
for installation reference.
(6) Remove second gear and needle bearing (Fig.
37).
(7) Remove second gear synchro ring, synchro fric-
tion cone, synchro cone and interm ring (Fig. 38).
(8) Remove 1-2 synchro hub snap ring.
(9) Position Bearing Splitter 1130 between first
and reverse gear. Press off 1-2 synchro hub, sleeve
and first gear from output shaft with shop press (Fig.
39).
(10) Remove first gear needle bearing (Fig. 40).
Fig. 36 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2-PIECE)
3 - WASHER LOCATING LUG
Fig. 37 SECOND GEAR
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 38 SECOND GEAR SYNCHRO RING & CONES
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
Fig. 39 HUB SLEEVE & 1-2 SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - BEARING SPLITTER 1130
Fig. 40 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 13
MANUAL TRANSMISSION - NV3500 (Continued)

(11) Remove output shaft bearing snap ring (Fig.
41).
(12) On 2-wheel drive models, remove output shaft
bearing.
(13) Remove fifth gear (Fig. 42).(14) Remove fifth gear needle bearing. Spread
bearing just enough to clear shoulder on output shaft
(Fig. 43).
(15) Remove fifth-reverse synchro hub snap ring
(Fig. 44).
Fig. 41 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 42 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 43 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig. 44 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
21 - 14 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(16) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 45).
(17) Remove reverse gear and needle bearing (Fig.
46).
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
Fig. 45 FIFTH-REVERSE SYNCHRO
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 46 REVERSE GEAR & NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
Fig. 47 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
DRMANUAL TRANSMISSION - NV3500 21 - 15
MANUAL TRANSMISSION - NV3500 (Continued)

INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball or internal components are worn or
damaged.
SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 48). Replace any fork
exhibiting wear or damage in these areas. Do not
attempt to salvage shift forks.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks or scores. The plunger spring should be
straight and not collapsed, or distorted. Minor
scratches or nicks on the plunger can be smoothed
with 320/400 grit emery soaked in oil. Replace the
plunger and spring if in doubt about condition. Check
condition of detent plunger bushings. Replace if dam-
aged.
Inspect shift shaft, shift shaft bushing, bearing,
shaft lever and lever bushing that fits over the lever.
Replace shaft if bent, cracked or severely scored.
Minor burrs, nicks or scratches can be smoothed off
with 320/400 grit emery cloth followed by polishing
with crocus cloth. Replace the shift shaft bushing or
bearing if damaged.Replace the shaft lever and bushing if either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the roll
pin that secures the lever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. These components
are NOT serviceable items. The front housing will
have to be replaced if the countershaft bearing race
is loose, worn or damaged. The rear housing will
have to be replaced if the countershaft rear bearing
race is loose, worn or damaged.
Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth and final
polished with oil coated crocus cloth. Replace the
retainer seal if necessary.
Fig. 48 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
21 - 16 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

Inspect output shaft bearing retainer, the
U-shaped retainer must be flat and free of distortion.
Replace the retainer if the threads are damaged or if
the retainer is bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, the front or rear hous-
ing must be replaced. A new countershaft bearing
will be supplied with each new housing for service
use.
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing if any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted or brinnelled. Also
replace the bearing if the plastic bearing cage is
damaged or distorted.
Replace thrust washer, wave washer or thrust
plate if cracked, chipped or worn. Replace idler gear
if the teeth are chipped, cracked or worn thin.
Replace shaft if worn, scored or the bolt threads are
damaged beyond repair. Replace support segment if
cracked or chipped and replace the idler attaching
bolts if the threads are damaged.
Shift Socket
Inspect the shift socket for wear or damage.
Replace the socket if the roll pin or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn or cracked. Do not reuse the original
shift socket roll pin. Install anewpin during assem-
bly. The socket roll pin is approximately 33 mm
(1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro-
ken teeth. Also check condition of the bearing bore in
each gear. The bores should be smooth and free of
surface damage. Discoloration of the gear bores is a
normal occurrence and is not a reason for replace-
ment. Replace gears only when tooth damage has
occurred or if the bores are brinnelled or severely
scored.
Inspect the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-aged or bearing surfaces are deeply scored, worn or
brinnelled.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use
Mopar Gasket Maker or equivalent for all case joints
and Mopar silicone sealer or equivalent for the
input shaft bearing retainer.
SYNCHRONIZER
(1) Slide sleeve onto the hub, leaving enough room
to install the spring in the hub and strut in the hub
groove.
(2) Install first spring in the hub, then install a
strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide sleeve onto the hub far enough to hold
the first strut and spring in place.
(4) Place detent ball in the top of the strut, then
press the ball into place with a small screwdriver.
Work the sleeve over the ball to hold it in place.
(5) Repeat procedure for the remaining springs,
struts and balls. Use tape or rubber bands to tempo-
rarily secure each strut and ball as they are
installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 49).
Fig. 49 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
DRMANUAL TRANSMISSION - NV3500 21 - 17
MANUAL TRANSMISSION - NV3500 (Continued)