boot DODGE RAM 2001 Service User Guide

CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions,
severe detonation can also separate the insulator
from the center electrode (Fig. 33). Spark plugs with
this condition must be replaced.
PREIGNITION DAMAGE
Preignition damage is usually caused by excessive
combustion chamber temperature. The center elec-
trode dissolves first and the ground electrode dis-
solves somewhat latter (Fig. 34). Insulators appear
relatively deposit free. Determine if the spark plug
has the correct heat range rating for the engine.
Determine if ignition timing is over advanced or if
other operating conditions are causing engine over-
heating. (The heat range rating refers to the operat-
ing temperature of a particular type spark plug.
Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thick-
ness and length of the center electrodes porcelain
insulator.)
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
35). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 2000 miles of opera-
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
REMOVAL
On 3.9L/5.2L/5.9L engines, spark plug cable heat
shields are pressed into the cylinder head to sur-
round each cable boot and spark plug (Fig. 36).
(1) Always remove spark plug or ignition coil
cables by grasping at the cable boot (Fig. 38). Turn
the cable boot 1/2 turn and pull straight back in a
steady motion. Never pull directly on the cable.
Internal damage to cable will result.
(2) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
around the spark plug. This will help prevent foreign
material from entering the combustion chamber.
(3) Remove the spark plug using a quality socket
with a rubber or foam insert.
(4) Inspect the spark plug condition. Refer to
Spark Plug Condition in the Diagnostics and Testing
section of this group.
Fig. 33 Chipped Electrode Insulator
1 - GROUND ELECTRODE
2 - CENTER ELECTRODE
3 - CHIPPED INSULATOR
Fig. 34 Preignition Damage
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
Fig. 35 Spark Plug Overheating
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
8I - 18 IGNITION CONTROLBR/BE
SPARK PLUG (Continued)

CLEANING
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After clean-
ing, file center electrode flat with a small point file or
jewelers file before adjusting gap.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
INSTALLATION
Special care should be taken when installing spark
plugs into the cylinder head spark plug wells. Be
sure the plugs do not drop into the plug wells as elec-
trodes can be damaged.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap or a cracked porcelain
insulator.
When replacing the spark plug and ignition coil
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise. It could cause cross ignition of the spark plugs
or short circuit the cables to ground.
(1) Start the spark plug into the cylinder head by
hand to avoid cross threading.
(2) Tighten spark plugs to 35-41 N´m (26-30 ft.
lbs.) torque.
(3) Install spark plug cables over spark plugs.
SPARK PLUG CABLE
DESCRIPTION
Spark plug cables are sometimes referred to as sec-
ondary ignition wires.
OPERATION
The spark plug cables transfer electrical current
from the ignition coil(s) and/or distributor, to individ-
ual spark plugs at each cylinder. The resistive spark
plug cables are of nonmetallic construction. The
cables provide suppression of radio frequency emis-
sions from the ignition system.
DIAGNOSIS AND TESTING - SPARK PLUG
CABLES
Cable routing is important on certain engines. To
prevent possible ignition crossfire, be sure the cables
are clipped into the plastic routing looms. Try to pre-
vent any one cable from contacting another. Before
removing cables, note their original location and
routing. Never allow one cable to be twisted around
another.
Check the spark plug cable connections for good
contact at the coil(s), distributor cap towers, and
spark plugs. Terminals should be fully seated. The
insulators should be in good condition and should fit
tightly on the coil, distributor and spark plugs. Spark
plug cables with insulators that are cracked or torn
must be replaced.
Clean high voltage ignition cables with a cloth
moistened with a non-flammable solvent. Wipe the
cables dry. Check for brittle or cracked insulation.
On 3.9L/5.2L/5.9L engines, spark plug cable heat
shields are pressed into the cylinder head to sur-
round each spark plug cable boot and spark plug
(Fig. 37). These shields protect the spark plug boots
from damage (due to intense engine heat generated
by the exhaust manifolds) and should not be
removed. After the spark plug cable has been
installed, the lip of the cable boot should have a
small air gap to the top of the heat shield (Fig. 37).
TESTING
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Fig. 36 Heat ShieldsÐ3.9L/5.2L/5.9L Engines
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
BR/BEIGNITION CONTROL 8I - 19
SPARK PLUG (Continued)

With the engine running, remove spark plug cable
from spark plug (one at a time) and hold next to a
good engine ground. If the cable and spark plug are
in good condition, the engine rpm should drop and
the engine will run poorly. If engine rpm does not
drop, the cable and/or spark plug may not be operat-
ing properly and should be replaced. Also check
engine cylinder compression.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.
Use an ohmmeter to test for open circuits, exces-
sive resistance or loose terminals. If equipped,
remove the distributor cap from the distributor.Do
not remove cables from cap.Remove cable from
spark plug. Connect ohmmeter to spark plug termi-
nal end of cable and to corresponding electrode in
distributor cap. Resistance should be 250 to 1000
Ohms per inch of cable. If not, remove cable from dis-
tributor cap tower and connect ohmmeter to the ter-
minal ends of cable. If resistance is not within
specifications as found in the SPARK PLUG CABLE
RESISTANCE chart, replace the cable. Test all spark
plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
To test ignition coil-to-distributor cap cable, do not
remove the cable from the cap. Connect ohmmeter to
rotor button (center contact) of distributor cap and
terminal at ignition coil end of cable. If resistance is
not within specifications as found in the Spark Plug
Cable Resistance chart, remove the cable from the
distributor cap. Connect the ohmmeter to the termi-
nal ends of the cable. If resistance is not within spec-
ifications as found in the Spark Plug Cable
Resistance chart, replace the cable. Inspect the igni-
tion coil tower for cracks, burns or corrosion.
REMOVAL
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 38). Grasp the boot (not the cable) and pull it
off with a steady, even force.
INSTALLATION
Install cables into the proper engine cylinder firing
order (Fig. 39), (Fig. 40) or (Fig. 41).
When replacing the spark plug and coil cables,
route the cables correctly and secure in the proper
retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise. It could
also cause cross ignition of the plugs or short circuit
the cables to ground.
Fig. 37 Heat ShieldsÐ3.9L/5.2L/5.9L Engines
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
Fig. 38 Cable Removal
1 - SPARK PLUG CABLE AND BOOT
2 - SPARK PLUG BOOT PULLER
3 - TWIST AND PULL
4 - SPARK PLUG
8I - 20 IGNITION CONTROLBR/BE
SPARK PLUG CABLE (Continued)

install locks and release tool. Tap the retainer with a
brass or heavy plastic hammer to ensure locks have
been seated.
(8) If valves and/or seats were ground, measure
the installed height of springs. Make sure the mea-
surement is taken from bottom of spring seat in cyl-
inder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. Ensure this brings spring height back to nor-
mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
(9) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSY
REMOVAL
(1) Disconnect spark plug wires by pulling the boot
straight out in line with plug.
(2) Remove cylinder head cover and gasket (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm bolts and the rocker
arm assembly (Fig. 26). Place rocker arm assemblies
on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm bolts to 28
N´m (21 ft. lbs.) torque.
(3) Install cylinder head cover and gasket (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(4) Connect spark plug wires.
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool,
Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
Fig. 26 Rocker Arm
1 - ROCKER ARMS
2 - ROCKER ARM PEDESTALS
3 - RETAINER
9 - 200 ENGINE 8.0LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shift lever
moves the selected shift rail, the shift fork attached
to that rail begins to move. The fork is positioned in
a groove in the outer circumference of the synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer does
this by having the synchronizer hub splined to the
mainshaft, or the countershaft in some cases, and
moving the blocker ring into contact with the gear's
friction cone. As the blocker ring and friction cone
come together, the gear speed is brought up or down
to the speed of the synchronizer. As the two speeds
match, the splines on the inside of the synchronizer
sleeve become aligned with the teeth on the blocker
ring and the friction cone and eventually will slide
over the teeth, locking the gear to the mainshaft, or
countershaft, through the synchronizer.
DIAGNOSIS AND TESTING - MANUAL
TRANSMISSION
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incor-
rect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, adaptor or extension housing, or from the front/
rear seals. A suspected leak could also be the result
of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Remove bolts attaching shift tower and lever
assembly to rear case. Then remove shift tower and
lever assembly.
(6) Raise vehicle on hoist.
(7) Remove crankshaft position sensor. Retain sen-
sor attaching bolts.
(8) Remove skid plate, if equipped.
(9) Drain transmission lubricant if transmission
will be disassembled for service.
(10) Mark propeller shaft/shafts and yoke/yokes for
installation reference and remove propeller shaft/
shafts.
(11) Disengage harness from clips on transmission
housing.
(12) Support engine with adjustable jack stand
and wood block.
(13) Drain transmission lubricant if transmission
will be disassembled for service.
BR/BEMANUAL - NV3500 21 - 3
MANUAL - NV3500 (Continued)

(5) Fill transmission to bottom edge of fill plug
hole with Mopar Transmission Lubricant.
(6) Install and tighten fill plug to 34 N´m (25 ft.
lbs.).
(7) Check transmission vent. Be sure vent is open
and not restricted.
INSTALLATION
NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.
Make sure transmission front housing mounting
surface is clean. Before installation apply light coat
of Mopar high temperature bearing grease to contact
surfaces of following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(1) Support and secure transmission to jack with
safety chains.
(2) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(3) Install and tighten transmission bolts to 54-61
N´m (40-45 ft. lbs.). Be sure front housing is fully
seated before tightening bolts. Install front dust
cover after all bolts are tightened.
(4) Fill transmission with Mopar lubricant. Correct
fill level is to bottom edge of fill plug hole.
(5) Connect backup lamp switch wires.(6) Connect transmission harnesses to clips on
case.
(7) Install crossmember. Tighten crossmember-to-
frame bolts to 68 N´m (50 ft. lbs.).
(8) Tighten crossmember-to-transmission insulator
nuts to 68 N´m (50 ft. lbs.).
(9) Install slave cylinder. Tighten cylinder nuts to
23 N´m (200 in. lbs.).
(10) Remove jack used to support transmission.
(11) Install strut bolts/nuts, if removed. Also
install oil filter if removal was necessary.
(12) Install and connect exhaust system. Align
exhaust components before tightening clamp and
bracket bolts and nuts. Be sure exhaust components
are clear of all chassis and driveline components.
TWO WHEEL DRIVE
(1) Align and install propeller shaft.
(2) Verify that all linkage components, hoses and
electrical wires have been connected.
(3) Remove any remaining support stands and
lower vehicle.
(4) Install crankshaft position sensor.
(5) Connect battery negative cable.
(6) Install shift tower and lever assembly. Tighten
shift tower bolts to 7-10 N´m (5-7 ft. lbs.).
(7) Install the shift lever extension onto the shift
tower and lever assembly.
(8) Install shift boot and bezel.
FOUR WHEEL DRIVE
(1) Install transfer case. Align and position trans-
fer case with transmission jack or aid of helper.
(2) Install and tighten transfer case attaching nuts
to 47 N´m (35 ft. lbs.).
(3) Install and connect transfer case shift linkage.
(4) Align and install front and rear propeller
shafts.
(5) Verify that all linkage components, hoses and
electrical wires have been connected.
(6) Check transfer case fluid level. Add Mopar
Dexron II, or ATF Plus if necessary. Correct level is
to edge of fill plug hole. Be sure transfer case is level
before checking or adding fluid.
(7) Check and adjust transfer case shift linkage if
necessary.
(8) Install transfer case skid plate, if equipped.
(9) Install crankshaft position sensor.
(10) Remove any remaining support stands and
lower vehicle.
(11) Connect battery negative cable.
(12) Install shift tower and lever assembly. Tighten
shift tower bolts to 7-10 N´m (5-7 ft. lbs.).
(13) Install the shift lever extension onto the shift
tower and lever assembly.
(14) Install shift boot and bezel.
Fig. 122 Shift Tower Bolts
1 - SHIFT TOWER AND LEVER ASSEMBLY
21 - 40 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
Fig. 4 NV4500 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
BR/BEMANUAL - NV4500 21 - 47
MANUAL - NV4500 (Continued)

INSTALLATION
NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.
Befor installation apply light coat of Mopar high
temperature bearing grease to contact surfaces of fol-
lowing components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(1) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(2) Mount transmission on jack and position trans-
mission under vehicle.
(3) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(4) Move transmission forward and start input
shaft in release bearing, clutch disc and pilot bush-
ing.
(5) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(6) Install and tighten transmission-to-clutch hous-
ing bolts to 108 N´m (80 ft. lbs.).
(7) Install transmission mount on transmission or
rear crossmember.
(8) Install rear crossmember.
(9) Remove transmission jack and engine support
fixture.
(10) Position transmission harness wires in clips
on shift cover.
(11) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(12) Connect speed sensor and backup light switch
wires.
TWO WHEEL DRIVE
(1) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(2) Align and install propeller shaft.
(3) Lower vehicle.
(4) Clean the mating surfaces of shift tower, isola-
tor plate, and shift cover with suitable wax and
grease remover.
(5) Apply Mopar Gasket Maker, or equivalent, to
the sealing surface of the shift cover. Do not over
apply sealant.(6) Install the isolator plate onto the shift cover,
metal side down.
(7) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(8) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
(9) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(10) Install the shift lever extension onto the shift
tower and lever assembly.
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install transfer case shift mechanism on trans-
mission.
(2) Install transfer case on transmission jack.
Secure transfer case to jack with safety chains.
(3) Raise jack and align transfer case input gear
with transmission mainshaft.
(4) Move transfer case forward and seat it on
adapter.
(5) Install and tighten transfer case attaching
nuts. Tighten nuts to 41-47 N´m (30-35 ft. lbs.) if
case has 3/8 studs, or 30-41 N´m (22-30 ft. lbs.) if
case has 5/16 studs.
(6) Install transfer case shift mechanism to side of
transfer case.
(7) Connect transfer case shift lever to range lever
on transfer case.
(8) Align and connect propeller shafts.
(9) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(10) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.) torque.
(11) Install exhaust system components.
(12) Lower vehicle.
(13) Clean the mating surfaces of shift tower, iso-
lator plate, and shift cover with suitable wax and
grease remover.
(14) Apply Mopar Gasket Maker, or equivalent, to
the sealing surface of the shift cover. Do not over
apply sealant.
(15) Install the isolator plate onto the shift cover,
metal side down.
(16) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(17) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
21 - 82 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(18) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(19) Install the shift lever extension onto the shift
tower and lever assembly.(20) Install shift lever boot and bezel.
(21) Connect battery negative cable.
SPECIFICATIONS
SPECIFICATIONS - NV4500
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Switch, Back-up Lamp 22-34 16-25 -
Countershaft Bearing Plate
Bolts19-26 14-19 170-230
Fifth Gear Nut 366-380 270-280 -
Fifth Gear Nut Clamp Bolt 13.5 10 -
Drain and Fill Plug 34-47 25-35 -
Front Bearing Retainer Bolts 27-34 20-25 235-305
Mainshaft Bearing Plate Bolts 19-26 14-19 170-230
PTO Cover Bolts 27-54 20-40 -
Extension/Adapter Housing
Bolts41-68 30-50 -
Shift Cover Bolt 27-31 20-23 -
SPECIAL TOOLS
MANUAL - NV4500
Remover Seal C-3985-B
Remover Bushing 6957
Remover, BushingÐ8155
Installer Bushing 6951
BR/BEMANUAL - NV4500 21 - 83
MANUAL - NV4500 (Continued)

SHIFT COVER
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission shift cover.
(5) Remove the shift tower and isolator plate from
the transmission shift cover.
INSTALLATION
(1) Clean the mating surfaces of shift tower, isola-
tor plate, and shift cover with suitable wax and
grease remover.(2) Apply MopartGasket Maker, or equivalent, to
the sealing surface of the shift cover. Do not over
apply sealant.
(3) Install the isolator plate onto the shift cover,
metal side down.
(4) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(5) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
(6) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(7) Install the shift lever extension, shift boot, and
bezel.
21 - 90 MANUAL - NV4500BR/BE