DODGE RAM 1500 1998 2.G Workshop Manual

(6) Install first gear stop ring in 1-2 synchro hub
and sleeve (Fig. 83). Verify stop ring is seated and
engaged in hub and sleeve.
(7) Install 1-2 synchro assembly and stop ring on
mainshaft with the taper on the sleeve facing for-
ward. (Fig. 84).(8) Install snap ring that secures 1-2 synchro on
mainshaft hub (Fig. 85). Verify snap ring is seated in
groove in mainshaft hub.
(9) Assemble second gear clutch cone, clutch ring
and stop ring (Fig. 86).
Fig. 83 FIRST GEAR STOP RING IN SYNCHRO HUB
Fig. 84 1-2 SYNCHRO
1 - MAINSHAFT HUB
2 - 1-2 SYNCHRO ASSEMBLY
3 - TAPERED SIDE OF SLEEVE
Fig. 85 1-2 SYNCHRO SNAP RING
1 - SYNCHRO SNAP RING
2 - 1-2 SYNCHRO ASSEMBLY
3 - MAINSHAFT HUB
Fig. 86 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - STOP RING
2 - CLUTCH RING
3 - CLUTCH CONE
21 - 68 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(10) Install assembled second gear clutch cone and
rings on mainshaft and in 1-2 synchro hub (Fig. 87).
(11) Install snap ring that secures second gear
clutch cone on mainshaft (Fig. 88). Use narrow blade
screwdriver to work snap ring into hub groove as
shown. Verify snap ring is seated in mainshaft
groove.
NOTE: If snap ring will not fit in groove, clutch cone
is slightly misaligned.(12) Install second gear bearing on mainshaft (Fig.
89).
(13) Install second gear on mainshaft and bearing.
Rotate gear until tabs of second gear clutch ring are
seated in tab slots in gear (Fig. 90).
Fig. 87 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - CLUTCH CONE
2 - STOP RING
3 - CLUTCH RING
Fig. 88 SECOND GEAR CLUTCH CONE SNAP RING
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
4 - SECOND GEAR CLUTCH CONE
Fig. 89 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
Fig. 90 SECOND GEAR
1 - SECOND GEAR
2 - CLUTCH RING TABS
3 - TAB SLOTS (IN GEAR)
DRMANUAL TRANSMISSION - NV4500 21 - 69
MANUAL TRANSMISSION - NV4500 (Continued)

(14) Install thrust washer pin in shaft (Fig. 91).
(15) Install second gear thrust washer. Verify
washer is seated on gear and pin (Fig. 92).
(16) Install second gear thrust washer snap ring
(Fig. 93). Verify snap ring is seated in mainshaft
groove.
(17) Install third gear bearing spacer on shaft and
seat it against thrust washer snap ring (Fig. 93).
(18) Install third gear bearing on mainshaft (Fig.
94). Bearing should be flush with mainshaft hub.
NOTE: If bearing is not flush with hub, the bearing
spacer or snap ring was not installed.
(19) Install third gear over bearing and onto main-
shaft (Fig. 95).
Fig. 91 THRUST WASHER PIN
1 - THRUST WASHER PIN
2 - SECOND GEAR
Fig. 92 SECOND GEAR THRUST WASHER
1 - SECOND GEAR
2 - SECOND GEAR THRUST WASHER
3 - LOCATING PIN IN WASHER NOTCH
Fig. 93 SNAP RING AND THIRD
1 - SECOND GEAR THRUST WASHER
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
Fig. 94 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 95 THIRD GEAR
1 - THIRD GEAR
21 - 70 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(20) Install synchro stop ring on third gear (Fig.
96). Verify stop ring is seated on cone taper.
(21) If 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align and install synchro sleeve on hub (Fig.
97).Front side of hub has a narrow groove
machined in it.
(b) Insert all three synchro struts in slots
machined in sleeve and hub (Fig. 97).
(c) Install and seat synchro springs (Fig. 97).
Use screwdriver to compress springs and seat them
in struts and hub as shown.(22) Start 3-4 synchro assembly on mainshaft with
the hub groove and sleeve groove both facing for-
ward. Tap assembly onto shaft splines until hub is
about 3 mm (0.125 in.) away from third gear stop
ring. Then align stop ring with synchro sleeve and
hub and seat synchro assembly with Installer C-4040
(Fig. 98).
(23) Verify 3-4 synchro hub is seated on shaft with
approximately 3 mm (0.125 in.) of shaft spline visi-
ble.
NOTE: If hub is not seated, stop ring lugs are mis-
aligned. Rotate ring until lugs are engaged in 3-4
hub slots.
(24) Verify that second and third gear rotate freely
at this point. If not, determine the cause and correct.
(25) Invert mainshaft in case or bench.
(26) Install first gear bearing on mainshaft.
(27) Install first gear on shaft with clutch hub side
of gear facing the front of shaft (Fig. 99). Verify tabs
on clutch ring are aligned and seated in first gear
hub.
NOTE: 1-2 synchro hub will not seat properly if
clutch ring tabs are misaligned.
Fig. 96 THIRD GEAR STOP RING
1 - SYNCHRO STOP RING
2 - THIRD GEAR
Fig. 97 SYNCHRO ASSEMBLY (3-4)
1 - STRUT (3)
2 - SPRING (3)
3 - 3-4 SLEEVE
4 - 3-4 HUB
Fig. 98 SEATING 3-4 SYNCHRO ASSEMBLY ON
MAINSHAFT
1 - 3-4 SYNCHRO HUB
2 - HUB GROOVE
3 - INSTALLER C-4040
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MANUAL TRANSMISSION - NV4500 (Continued)

(28) Install reverse clutch gear on first gear (Fig.
99). Verify clutch gear is seated on shaft splines.
(29) Install reverse clutch gear snap ring with
heavy duty snap ring pliers (Fig. 99). Verify snap
ring is seated in groove.
NOTE: Reverse gear will not fit properly if snap ring
is not seated.
(30) Install stop ring on clutch cone (Fig. 100). Ver-
ify stop ring is seated on cone taper.
(31) Install reverse gear bearing spacer on main-
shaft and seat against reverse clutch gear snap ring
(Fig. 101).
(32) Install reverse gear bearing on mainshaft
(Fig. 101).
(33) If reverse gear sleeve and struts were disas-
sembled for service, reassemble sleeve, struts and
springs as follows:CAUTION: The reverse sleeve will fit either way on
the hub. Verify tapered side of the sleeve faces
rearward.
(a) Position sleeve on hub so tapered side of
sleeve faces rearward. (Fig. 102).
(b) Rotate sleeve to align teeth on sleeve and
hub. Sleeve will slide easily into place on hub when
properly aligned.
(c) Install springs in gear hub (Fig. 102). Use
petroleum jelly to hold springs in place if desired.
Fig. 102 REVERSE GEAR SYNCHRO ASSEMBLY
1 - REVERSE GEAR
2 - SLEEVE
3 - SPRING (3)
4 - STRUT (3)
5 - HUB
Fig. 99 FIRST GEAR AND CLUTCH GEAR
1 - FIRST GEAR
2 - REVERSE CLUTCH GEAR SNAP RING
3 - REVERSE CLUTCH GEAR
Fig. 100 CLUTCH GEAR STOP RING
1 - REVERSE GEAR STOP RING
2 - CLUTCH GEAR
3 - FIRST GEAR
Fig. 101 REVERSE GEAR BEARING AND SPACER
1 - REVERSE GEAR BEARING
2 - BEARING SPACER
3 - FIRST GEAR
21 - 72 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(d) Compress first spring with flat blade screw-
driver and slide strut into position in hub slot.
Then work spring into seat in strut with small
hooked tool or screwdriver.
(e) Install second and third struts in same man-
ner as described in step (d).
(f) Work sleeve upward on hub until struts are
centered and seated in sleeve. Sleeve should be in
neutral position after seating struts.
(34) Install reverse gear and synchro assembly on
mainshaft (Fig. 103). Rotate assembly until stop ring
lugs engage in hub slots and gear drops into seated
position.
(35) Install reverse gear thrust washer (Fig. 104).
(36) Install rear bearing on mainshaft with
Installer 6446. Seat bearing on output shaft and
against thrust washer (Fig. 105).
(37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 106).
(38) Install fourth gear clutch gear in stop ring
(Fig. 107).
Fig. 103 REVERSE GEAR
1 - REVERSE GEAR AND SYNCHRO ASSEMBLY
Fig. 104 REVERSE GEAR THRUST WASHER
1 - THRUST WASHER
2 - REVERSE GEAR
Fig. 105 MAINSHAFT REAR BEARING
1 - INSTALLER
2 - MAINSHAFT REAR BEARING
Fig. 106 FOURTH GEAR STOP RING
1 - 3-4 SYNCHRO SLEEVE
2 - FOURTH SPEED STOP RING
Fig. 107 FOURTH GEAR CLUTCH GEAR
1 - FOURTH SPEED CLUTCH GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 73
MANUAL TRANSMISSION - NV4500 (Continued)

(39) Roll gear case onto its left side.
(40) Grip mainshaft at pilot bearing hub and just
behind reverse gear. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
(41) Continue holding front of shaft but switch
grip at rear to shaft output splines. Lift mainshaft
assembly slightly, align gears and seat assembly in
case.
(42) Set transmission case upright (Fig. 108).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 109). Use plenty of petroleum jelly to hold bear-
ing in place.
(44) Check alignment and mesh of mainshaft
gears. If gears are not aligned, roll case on side and
realign shaft and gears in case.DRIVE GEAR AND RETAINER
(1) Install bearing on drive gear with Installer
6448 (Fig. 110).
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear
rearward until mainshaft hub is seated in pilot bear-
ing.
(4) Install bearing cup in front retainer with Han-
dle C-4171 and Installer C-4308 (Fig. 111).
Fig. 108 MAINSHAFT AND GEARTRAIN IN CASE
1 - MAINSHAFT AND GEARTRAIN
2 - FOURTH SPEED CLUTCH GEAR
Fig. 109 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 110 FRONT BEARING ON DRIVE GEAR
1 - INSTALLER
2 - BEARING
3 - DRIVE GEAR
Fig. 111 FRONT BEARING CUP IN RETAINER
1 - INSTALLER
2 - HANDLE
3 - WOOD BLOCKS
4 - RETAINER
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MANUAL TRANSMISSION - NV4500 (Continued)

(5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 112). Use one or two wood
blocks to support retainer as shown. Lubricate seal
lip with petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover.
(7) Apply Mopar Silicone Sealer or equivalent to
flange surface of front bearing retainer (Fig. 113).
(8) Install front bearing retainer over drive gear
and start it into case.
(9) Start front bearing retainer in gear case. Verify
retainer lube channel is at the top-center(12
O'clock)position (Fig. 113).(10) Align front bearing retainer bolt holes and tap
retainer into place with plastic mallet. Installnew
retainer bolts and tighten to 30 N´m (22 ft. lbs.) (Fig.
114).
NOTE: Never reuse the old bolts.
MAINSHAFT END PLAY
(1) Install mainshaft rear bearing cup in case and
over bearing. Tap bearing cup into place with plastic
mallet.
(2) Install rear bearing plate to hold mainshaft
and rear bearing in position (Fig. 115).
NOTE: Do not install any end play shims at this
time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case in upright position on bench.
Either cut hole in bench to accept drive gear and
front retainer or use C-clamps to secure transmission
on bench.
NOTE: Do not leave transmission unsupported.
(5) Install Extension Rod 8161 into a suitable
threaded hole in rear of case.
(6) Mount dial indicator on extension rod and posi-
tion indicator plunger against end of mainshaft.
(7) Move mainshaft forward to remove all play
then zero dial indicator.
(8) Move mainshaft upward and record dial indica-
tor reading. Move mainshaft with pry tool positioned
between drive gear and case.
(9) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play.
If end play adjustment is required, remove bearing
plate and install necessary shim.
(10) Reinstall rear bearing plate with oil hole in
bearing plate at the top (Fig. 115).
(11) Apply Mopar Lock N' Seal or equivalent to
bearing plate bolt threads. Install and tighten bolts
to 23 N´m (200 in. lbs.).
Fig. 112 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - RETAINER
3 - WOOD BLOCK
Fig. 113 LOCATION OF FRONT RETAINER LUBE
CHANNEL
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 114 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
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MANUAL TRANSMISSION - NV4500 (Continued)

(12) Install mainshaft fifth gear with Installer
6446 (Fig. 116). Gear is seated when it contacts rear
bearing.
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) Install thrust washer pin in countershaft (Fig.
117).
(2) Install thrust washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 118).
NOTE: The flat side of washer faces the rear and
cone side faces the front.
(3) Lubricate and install fifth gear bearing on
countershaft (Fig. 119).
Fig. 115 REAR BEARING PLATE
1 - BEARING PLATE OIL HOLE (AT TOP)
2 - MAINSHAFT REAR BEARING PLATE
Fig. 116 MAINSHAFT FIFTH GEAR
1 - MAINSHAFT FIFTH GEAR
2 - INSTALLER
Fig. 117 FIFTH GEAR THRUST WASHER PIN
1 - THRUST WASHER PIN
2 - COUNTERSHAFT
Fig. 118 FIFTH GEAR THRUST WASHER
1 - PIN
2 - THRUST WASHER
Fig. 119 COUNTERSHAFT FIFTH GEAR BEARING
1 - COUNTERSHAFT
2 - FIFTH GEAR NEEDLE BEARING
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MANUAL TRANSMISSION - NV4500 (Continued)

(4) Install synchro sleeve on hub of countershaft
fifth gear with tapered side of sleeve facing front and
the flat side facing rear (Fig. 120).
(5) Install shift fork in synchro sleeve (Fig. 121).(6) Install assembled fifth gear, synchro sleeve and
shift fork (Fig. 122). Align fork with shift lug rail and
align gear with bearings and countershaft. Start
components onto shaft and rail, then tap gear and
fork into place with plastic or rawhide mallet.
(7) Install fifth gear synchro struts and springs
(Fig. 123).
Fig. 120 SYNCHRO SLEEVE ON COUNTERSHAFT
FIFTH
1 - GEAR HUB
2 - SYNCHRO SLEEVE
3 - COUNTERSHAFT FIFTH GEAR
Fig. 121 FIFTH GEAR SHIFT FORK IN SYNCHRO
SLEEVE
1 - SYNCHRO SLEEVE
2 - SHIFT FORK
Fig. 122 COUNTERSHAFT FIFTH GEAR, SHIFT
FORK AND SYNCHRO SLEEVE
1 - SHIFT FORK AND SLEEVE
2 - FIFTH GEAR HUB
3 - SHIFT FORK ROLL PINS
Fig. 123 FIFTH GEAR SYNCHRO STRUTS AND
SPRINGS
1 - FIFTH GEAR HUB
2 - SYNCHRO SPRING (3)
3 - SYNCHRO STRUT (3)
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MANUAL TRANSMISSION - NV4500 (Continued)