DODGE RAM 2001 Service Repair Manual

Fig. 75 Synchro Sleeve Locations
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCHRO SLEEVE
8 - 3-4 SYNCHRO SLEEVE
Fig. 76 Idler Gear And Bearing
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFTFig. 77 Idler Gear Rear Thrust Washer
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
21 - 26 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 78).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 78). Verify snap
ring is seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/
BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
(2) If necessary, the shift shaft bushing can be
replaced as follows:
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.
(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.
(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case.(3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case.
(4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive
the detent bushings through the outer case and
into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
the case.
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
GEARTRAIN ASSEMBLY
(1) Install Adapter 6747-1A on input shaft hub of
Fixture 6747 (Fig. 79). Then install Adapter 6747-2B
on front bearing hub of countershaft. Be sure the
shoulder is seated against the countershaft.
(2) Install input shaft in fixture tool. Make sure
Adapter Tool 6747-1A is positioned under shaft as
shown (Fig. 80).
(3) Install pilot bearing in input shaft (Fig. 80).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
Fig. 78 Idler Gear And Shaft Assembly
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
BR/BEMANUAL - NV3500 21 - 27
MANUAL - NV3500 (Continued)

(4) Install fourth gear synchro ring on input shaft
(Fig. 81).
(5) Adjust height of idler gear pedestal on assem-
bly fixture (Fig. 82). Start with a basic height of 18.4
cm (7-1/4 in.). Final adjustment can be made after
gear is positioned on pedestal.
Fig. 79 Fixture For Geartrain Build-up
1 - ADAPTER 6747-2B
2 - CUP 8115
3 - ADAPTER 6747-1A
4 - FIXTURE 6747
Fig. 80 Pilot Bearing And Input Shaft
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 81 Fourth Gear Synchro
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 82 Idler Pedestal Base Height
1 - REVERSE IDLER PEDESTAL
21 - 28 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(6) Install assembled output shaft and geartrain in
input shaft (Fig. 83). Carefully rotate output shaft
until the 3-4 synchro ring seats in synchro hub and
sleeve.
(7) Install Adapter 6747-2B on front bearing hub
of countershaft, if not previously done. The shoulder
goes toward the countershaft.
(8) Slide countershaft (and adapter) into fixture
slot. Verify countershaft and output shaft gears are
fully meshed with the mainshaft gears before pro-
ceeding (Fig. 84).(9) Check alignment of countershaft and output
shaft gear teeth. Gears may not align perfectly a dif-
ference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.)
will probably exist. This difference will not interfere
with assembly. If difference is greater than this, the
countershaft adapter tool is probably upside down.
Remove countershaft, reverse adapter tool, reinstall
countershaft and check alignment again.
(10) Position reverse idler in support cup of assem-
bly fixture (Fig. 85). Verify idler gear is properly
meshed and aligned with shaft gear teeth and that
bolt holes are facing out from the geartrain. Adjust
pedestal up or down if necessary and verify short end
of idler shaft is facing up as shown.
Fig. 83 Output Shaft And Geartrain Installed In Input
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE 6747
Fig. 84 Countershaft On Fixture Tool
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
BR/BEMANUAL - NV3500 21 - 29
MANUAL - NV3500 (Continued)

(11) On 2-wheel drive transmission, thread one
Alignment Pin 8120 in center or passenger side hole
of output shaft bearing retainer. Then position
retainer on fifth gear as shown (Fig. 86).(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
87). Arm of fifth-reverse fork goes through slot in 1-2
fork.
(13) Install assembled shift forks in synchro
sleeves and verify forks are seated in sleeves (Fig.
88).
Fig. 85 Reverse Idler Assembly On Assembly
Fixture Tool
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - TOOL PEDESTAL
Fig. 86 Positioning Output Shaft Bearing Retainer
1 - PIN 8120
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 87 1-2 And Fifth-Reverse Shift Forks
1 - INSERT ARM THROUGH 1-2 FORK
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
Fig. 88 Shift Forks In Synchro
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
21 - 30 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

REAR HOUSING - 2WD
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 89).
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 90).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 91).
(4) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 91).
(6) Reach into countershaft rear bearing with fin-
ger and push each bearing roller outward against the
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
Fig. 89 Rear Housing Dowels
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
Fig. 90 Countershaft Rear
1 - COUNTERSHAFT REAR BEARING
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY (APPLY TO BEARING AND RACE)
Fig. 91 Countershaft Bearing
1 - SHIFT SHAFT BUSHING/BEARING
2 - COUNTERSHAFT REAR BEARING (SEATED IN RACE)
BR/BEMANUAL - NV3500 21 - 31
MANUAL - NV3500 (Continued)

(7) Install rear housing onto geartrain (Fig. 92)
and verify bearing retainer pilot stud is in correct
bolt hole in housing. Be sure countershaft and output
shaft bearings are aligned in housing and on counter-
shaft.
NOTE: It may be necessary to lift upward on coun-
tershaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
(9) Apply Mopar Gasket Maker or equivalent to
housing bolt threads, bolt shanks and under bolt
heads (Fig. 93).
(10) Start first two bolts in retainer (Fig. 94). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 94).
(12) Tighten all three retainer bolts to 30-35 N´m
(22-26 ft. lbs.).
ADAPTER HOUSING - 4WD
(1) Install rear bearing in adapter housing. Use
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 95).
Fig. 92 Rear Housing - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 93 Housing Bolts
1 - MOPAR GASKET MAKER (OR LOCTITE 518)
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 94 Pilot Stud Tool And Retainer Bolts - 2WD
1 - BEARING RETAINER BOLT
2 - PIN 8120
21 - 32 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(3) Apply Mopar Gasket Maker or equivalent to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 93).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 91).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 91).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 91).
(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 96).
(10) Lubricate lip of new rear seal (Fig. 97) with
MopartDoor Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 97).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify that all synchro sleeves are in Neutral
position (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position for reassembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
Fig. 95 Adapter Housing - 4WD
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
Fig. 96 Rear Bearing Snap Ring - 4WD
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 97 Rear Seal
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
BR/BEMANUAL - NV3500 21 - 33
MANUAL - NV3500 (Continued)

(2) Install 3-4 shift fork in synchro sleeve (Fig. 98).
Verify groove in fork arm is aligned with grooves in
1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
99)with shaft detent notches to the rear.
(4) Assemble shift shaft shift lever and bushing
(Fig. 100). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 101).(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
102).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 103).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
Fig. 98 3-4 Shift Fork
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 99 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 100 Shift Shaft Lever And Bushing
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 101 Install Shift Shaft Lever And Bushing
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
21 - 34 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-
mission will have to be disassembled again to cor-
rect shaft alignment.
(9) Select correctnewroll pin for shift shaft lever
(Fig. 104). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 105).(11) Seat shaft lever roll pin with pin punch (Fig.
106).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 106).
(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 107).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket after installation
(Fig. 108).
(15) Verify that notches in shift fork arms are
aligned. Realign arms if necessary.
Fig. 102 Inserting Shaft Into Lever Opening
1 - SHIFT SHAFT
Fig. 103 Shift Socket
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 104 Roll Pin Identification
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 105 Roll Pin In Shift Socket
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
BR/BEMANUAL - NV3500 21 - 35
MANUAL - NV3500 (Continued)