light DODGE RAM 2001 Service Repair Manual

(5) Apply 1/8 in. wide bead of MopartGasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 111).
(6) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(9) Place transmission in horizontal position.
(10) Apply MopartGasket Maker or equivalent, to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 112).
(11) Install and start housing attaching bolts by
hand (Fig. 112). Then tighten bolts to 34 N´m (25 ft.
lbs.).
(12) Install shift shaft bushing lock bolt (Fig. 113).
Apply Mopar Gasket Maker or equivalent to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubricate then install shift shaft detent
plunger in housing bore (Fig. 114). Lubricate plunger
with petroleum jelly or gear lubricant. Verify plunger
is fully seated in detent notch in shift shaft.
(14) Install detent spring inside plunger (Fig. 114).
(15) Install detent plug in end of Installer 8123.
Position plug on detent spring and compress spring
until detent plug pilots in detent plunger bore. Drive
detent plug into transmission case until plug seats.
(16) Install backup light switch (Fig. 115).
Fig. 110 Countershaft Front Bearing
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 111 Seal Front/Rear Housings
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 112 Housing Bolts
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
BR/BEMANUAL - NV3500 21 - 37
MANUAL - NV3500 (Continued)

(17) Install input shaft snap ring (Fig. 116).
(18) Installnewoil seal in front bearing retainer
with Installer 6448 (Fig. 117).
(19) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
118).
(20) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
119). Verify bolt holes are aligned before seating
retainer.
CAUTION: Be sure sealer does not get into the oil
feed hole in the transmission case or bearing
retainer.
Fig. 113 Shift Shaft Bushing Lock Bolt
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 114 Shift Shaft Detent Plunger
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
Fig. 115 Backup Light Switch
1 - BACKUP LIGHT SWITCH
Fig. 116 Shaft Snap Ring - Typical
1 - INPUT SHAFT SNAP RING
Fig. 117 Oil Seal In Front Bearing Retainer
1 - INSTALLER 6448
2 - FRONT BEARING RETAINER
21 - 38 MANUAL - NV3500BR/BE
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)

(18) Remove bolts attaching mainshaft rear bear-
ing plate to gear case and remove fifth gear plate end
play shims and bearing cup (Fig. 18).
FRONT RETAINER
(1) Remove front retainer bolts (Fig. 19). Discard
retainer bolts. They should not be reused.
(2) Remove retainer by lightly tapping it back and
forth with plastic mallet. Then rock retainer back
and forth by hand to work it out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
(3) Remove seal from front retainer (Fig. 20). Col-
lapse one side of seal then pry it out with pry tool.(4) To remove front retainer bearing cup, assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
21).
(5) Insert Puller Jaws 6453-1 in puller flange (Fig.
21). Narrow lip of puller jaws will go under bearing
cup.
(6) Install Disc C-4487-1 into bearing retainer on
heavy duty transmissions for Insert 6453-2 to rest
upon.
Fig. 18 Mainshaft Fifth Gear Bearing Plate, Bearing
Shims, And Rear Bearing Cup
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 19 Front Bearing Retainer
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
Fig. 20 Bearing Retainer Seal
1 - SEAL
2 - FRONT BEARING RETAINER
Fig. 21 Puller Rods, Flange And Jaws
1 - RODS 6444-4
2 - FLANGE 6444-1
3 - JAWS 6453-1
21 - 52 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 27).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 28).
(4) Roll gear case onto left side (Fig. 29).
(5) To remove mainshaft assembly (Fig. 29) lift
front end of mainshaft slightly.
NOTE: Handling mainshaft carfully because gears
are lose on the mainshaft.
(6) Grasp mainshaft rear splines, then turn spline
end of mainshaft counterclockwise to rotate shaft and
geartrain out of case. Tilt mainshaft outward and
removed from case.
Fig. 25 Pilot Bearing
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 26 Front Bearing Puller
1 - PULLER 6444
2 - RODS 6444-6
3 - JAWS 6447
4 - COLLAR 6444-8
5 - FLANGE 6444-1
6 - DRIVE GEAR
Fig. 27 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 28 Fourth Gear Clutch Gear Stop Ring
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
21 - 54 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 40).
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 41). A small pin punch can be mod-
ified by putting a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 41).(4) Remove shift lug rail.
MAINSHAFT
NOTE: Not all of the mainshaft gear and synchro
components are a one-way fit. Some gear and syn-
chro components can be installed backwards. Paint
or scriber gear and synchro components for instal-
lation reference. Then stack geartrain parts in order
of removal to avoid incorrect assembly.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Remove 3-4 synchro hub, third gear stop ring
and third gear as an assembly (Fig. 42).
Fig. 40 Countershaft Front Bearing Cup
1 - REMOVER 6454
2 - HANDLE C-4171
Fig. 41 Shift Lug Roll Pin
1 - PUNCH
2 - 30É BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
Fig. 42 Third Gear, Stop Ring, And 3-4 Hub
1 - THIRD GEAR
2 - THIRD GEAR STOP RING
3 - 3-4 SYNCHRO HUB
21 - 58 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(10) Install assembled second gear clutch cone and
rings on mainshaft and in 1-2 synchro hub (Fig. 86).
(11) Install snap ring that secures second gear
clutch cone on mainshaft (Fig. 87). 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.
Fig. 84 1-2 Synchro Snap Ring
1 - SYNCHRO SNAP RING
2 - 1-2 SYNCHRO ASSEMBLY
3 - MAINSHAFT HUB
Fig. 85 Second Gear Clutch Cone, Clutch Ring And
Stop Ring
1 - STOP RING
2 - CLUTCH RING
3 - CLUTCH CONE
Fig. 86 Second Gear Clutch Cone, Clutch Ring And
Stop Ring
1 - CLUTCH CONE
2 - STOP RING
3 - CLUTCH RING
Fig. 87 Second Gear Clutch Cone Snap Ring
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
4 - SECOND GEAR CLUTCH CONE
BR/BEMANUAL - NV4500 21 - 71
MANUAL - NV4500 (Continued)

(37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 105).
(38) Install fourth gear clutch gear in stop ring
(Fig. 106).
(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. 107).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 108). 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. 109).
(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. 110).
(5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 111). 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.
Fig. 105 Fourth gear Stop Ring
1 - 3-4 SYNCHRO SLEEVE
2 - FOURTH SPEED STOP RING
Fig. 106 Fourth gear Clutch Gear
1 - FOURTH SPEED CLUTCH GEAR
Fig. 107 Mainshaft And Geartrain In Case
1 - MAINSHAFT AND GEARTRAIN ASSEMBLY
2 - FOURTH SPEED CLUTCH GEAR
Fig. 108 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
21 - 76 MANUAL - NV4500BR/BE
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)