DODGE RAM 2001 Service Repair Manual

(10) Remove shift shaft detent plug with Remover
8117A. Attach fingers of the remover to the detent
plug and push the cup down till it contacts the trans.
Then tighten the nut till it pulls the plug from the
case.
(11) Remove shift shaft detent plunger and spring
with a pencil magnet.
(12) Remove bolts that attach front housing to rear
housing (Fig. 9). Three bolts at extreme rear of hous-
ing are actually for the output shaft bearing retainer.
It is not necessary to remove all three bolts at this
time. Leave at least one bolt in place until geartrain
is ready to be removed from case.
(13) Separate front housing from rear housing
(Fig. 10). Use plastic hammer to tap front housing off
alignment dowels.
(14) Remove and inspect input shaft bearing.
Inspect countershaft front bearing race (Fig. 11).
Fig. 7 Input Shaft Bearing Retainer
1 - SHAFT BEARING
2 - BEARING RETAINER
3 - INPUT SHAFT
Fig. 8 Input Shaft
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
Fig. 9 Housing And Bearing Retainer Bolt
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
Fig. 10 Front Housing
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
21 - 6 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(15) Note position of input shaft, shift shaft and
forks, and geartrain components in housing (Fig. 12).
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Unseat shift socket roll pin with Remover 6858.
Position remover on shift shaft and center tool over
the roll pin. Verify tool legs are firmly seated on the
shift socket (Fig. 13).
(2) Tilt socket toward the side of the case to avoid
trapping the pin between the gear teeth.
(3) Tighten remover to press the roll pin down-
ward and out of the shift socket (Fig. 13).
NOTE: Roll pin does not have to be completely
removed, the pin must only be clear of the shift
shaft. Be careful not to push the pin into the
geartrain.
(4) Drive out shift bushing and lever roll pint with
a hammer and punch (Fig. 14).
NOTE: Use proper size punch to avoid bending the
shift shaft.
(5) Pull shift shaft straight out of rear housing,
shift socket, fifth-reverse fork and 1-2 fork (Fig. 15).
(6) Remove shift socket from rear housing (Fig.
16).
(7) Remove lever and bushing (Fig. 17).
(8) Remove 3-4 fork. Rotate 3-4 fork around syn-
chro sleeve until fork clears shift arms on 1-2 and
fifth-reverse forks. Then remove 3-4 fork (Fig. 18).
Fig. 11 Input Shaft Bearing and Countershaft Front
Bearing Race
1 - INPUT SHAFT BEARING
2 - FRONT HOUSING
3 - COUNTERSHAFT FRONT BEARING
Fig. 12 Geartrain And Shift Components
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
Fig. 13 Shift Socket
1 - REMOVER 6858
2 - SHIFT SOCKET
BR/BEMANUAL - NV3500 21 - 7
MANUAL - NV3500 (Continued)

(9) Remove the reverse idler shaft support bolt
(front bolt) (Fig. 19).
(10) Loosen rear reverse idler shaft bolt (rear bolt)
(Fig. 19).
(11) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(12) 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 6747-2B on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 20).
(d) Stand geartrain and rear housing upright on
fixture (Fig. 21). Have helper hold fixture tool in
place while housing and geartrain is being rotated
into upright position.
Fig. 14 Shift Shaft Lever And Bushing Roll Pin
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 15 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 16 Shift Socket And Roll
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 17 Shift Shaft Lever And Bushing
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 18 3-4 Shift Fork
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
21 - 8 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(13) Remove rear bolt holding reverse idler shaft
in housing.
REAR HOUSING - 2WD
(1) On 2-wheel drive transmission, remove three
bolts that attach output shaft bearing retainer to
rear case (Fig. 22). Bolts are rear of shift tower open-
ing.
Fig. 19 Reverse Idler Shaft/Support
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 20 Fixture Assembly
1 - FIXTURE 6747
2 - ADAPTER 6747-1A
3 - CUP 8115
4 - REVERSE IDLER PEDESTAL
5 - ADAPTER 6747-2B
Fig. 21 Geartrain And Housing Mounted On Fixture
1 - INPUT SHAFT
2 - COUNTERSHAFT
3 - FIXTURE 6747
Fig. 22 Output Shaft
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
BR/BEMANUAL - NV3500 21 - 9
MANUAL - NV3500 (Continued)

(2) Unseat output shaft bearing from bearing bore
in rear housing. With a plastic/rawhide hammer tap
rear housing upward and off output shaft bearing
(Fig. 23).
(3) Lift rear housing up and off geartrain (Fig. 24).
(4) Remove countershaft rear bearing from coun-
tershaft (Fig. 25).
(5) Examine condition of bearing bore and idler
shaft notch in rear housing . Replace housing if any
of these components are damaged.
Fig. 23 Seperate Rear Housing From Output Shaft
Bearing - 2WD
1 - REAR HOUSING
2 - PLASTIC OR RAWHIDE MALLET
3 - FIXTURE 6747
Fig. 24 Rear Housing - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 25 Countershaft Rear Bearing
1 - COUNTERSHAFT REAR BEARING
2 - OUTPUT SHAFT
3 - COUNTER SHAFT
21 - 10 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

REAR ADAPTER HOUSING - 4WD
(1) Locate dimples in face of rear seal (Fig. 26).
With a slide hammer mounted screw remove seal by
inserting screw into seal at dimple locations (Fig. 27).(2) Remove rear bearing snap ring from output
shaft with snap ring pliers (Fig. 28).
(3) Lift rear adapter housing upward and off
geartrain (Fig. 29).
(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 30). Use ham-
mer handle to push or tap bearing out of housing if
needed.
(5) Examine condition of bearing bore, counter-
shaft rear bearing race and idler shaft notch in rear
housing. Replace housing if race, bore or notch are
worn or damaged.
Fig. 26 Dimples In Seal Face - 4WD
1 - LOCATION OF DIMPLES
2 - SEAL FACE
Fig. 27 Rear Seal - 4WD
1 - SLIDE HAMMER
2 - REMOVER TOOL
3 - REAR SEAL
Fig. 28 Rear Bearing Snap Ring - 4WD
1 - HEAVY DUTY SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 29 Rear Adapter Housing
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
BR/BEMANUAL - NV3500 21 - 11
MANUAL - NV3500 (Continued)

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 assembly fixture tool.
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. Remove each
synchronizer unit as an assembly to avoid intermix-
ing 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) Remove 3-4 synchro assembly, third gear syn-
chro ring and third gear with shop press and Bearing
Splitter 1130. Position splitter between second and
third gears.
(3) Remove third gear needle bearing (Fig. 31).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft with a small pry tool (Fig.
32).
Fig. 30 Rear Adapter Housing Components
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 31 Third Gear Needle Bearing
1 - THIRD GEAR NEEDLE BEARING
Fig. 32 Thrust Washer
1-PRYTOOL
2 - THRUST WASHER RETAINING RING
21 - 12 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(5) Remove two-piece thrust washer (Fig. 33). Note
position of washer locating lugs in shaft notches for
installation reference.
(6) Remove second gear and needle bearing (Fig.
34).(7) Remove second gear synchro ring, synchro fric-
tion cone, and synchro cone (Fig. 35).
(8) Remove interm ring.
(9) Remove 1-2 synchro hub snap ring.
(10) Remove 1-2 synchro hub and sleeve and first
gear from output shaft with shop press and Bearing
Splitter 1130 (Fig. 36). Position splitter between first
and reverse gears.
Fig. 33 Two-Piece Thrust Washer
1 - SECOND GEAR
2 - THRUST WASHER (2-PIECE)
3 - WASHER LOCATING LUG
Fig. 34 Second Gear
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 35 Second Gear Synchro Ring And Cones
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
Fig. 36 Hub Sleeve And 1-2 Synchro
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - SPLITTER 1130
BR/BEMANUAL - NV3500 21 - 13
MANUAL - NV3500 (Continued)

(11) Remove first gear needle bearing (Fig. 37).
(12) Remove output shaft bearing snap ring (Fig.
38).
(13) On 2-wheel drive models, remove output shaft
bearing.
(14) Remove fifth gear (Fig. 39).
(15) Remove fifth gear needle bearing, spreading
bearing apart just enough to clear shoulder on output
shaft (Fig. 40).
(16) Remove fifth-reverse synchro hub snap ring
(Fig. 41).
(17) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 42).
(18) Remove reverse gear and needle bearing (Fig.
43).
Fig. 37 First Gear Needle Bearing
1 - FIRST GEAR NEEDLE BEARING
Fig. 38 Output Shaft Bearing Snap Ring
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 39 Fifth Gear
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 40 Fifth Gear Needle
1 - FIFTH GEAR NEEDLE BEARING
Fig. 41 Fifth-Reverse
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
21 - 14 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 44).
(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 trans-
mission housings with a standard parts cleaning sol-
vent. Do not use acid or corrosive base solvents. Dry
all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such
as Mopartdegreasing 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.
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. 45). 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 damaged.
Inspect the shift shaft, shift shaft bushing and
bearing, the shaft lever, and the lever bushing that
fits over the lever. Replace the 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.
Fig. 42 Fifth-Reverse Synchro
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 43 Reverse Gear And Needle Bearing
1 - REVERSE GEAR AND NEEDLE BEARING
BR/BEMANUAL - NV3500 21 - 15
MANUAL - NV3500 (Continued)