DODGE RAM 2002 Service Repair Manual

(18) Remove mainshaft rear bearing plate bolts
and remove fifth gear plate end play shims and bear-
ing cup (Fig. 18).
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 19). Do not reused retainer bolts.(2) Lightly tapping retainer 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 front retainer seal by (Fig. 20) collaps-
ing one side of seal then prying it out.
(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. 16 Retaining Collar Over Puller Jaws
1 - JAWS 6459 or 6820
2 - COLLAR 6444-8
Fig. 17 Fifth Gear From Mainshaft Splines
1 - COLLAR 6444-8
2 - JAWS 6459 OR 6820
3 - BOLT 6444
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE 6444-1
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
21 - 8 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(7) Install assembled tools in front retainer (Fig.
22) with puller jaws seated under bearing cup.
(8) Place Insert Tool 6453-2 in center of puller
jaws, to hold puller jaws in place (Fig. 22).
(9) Install Puller 6444 on puller rods (Fig. 23) and
install retaining nuts on puller rods.
(10) Tighten puller bolt to draw bearing cup out of
retainer (Fig. 23).
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
Fig. 22 Puller Tools In Front Retainer
1 - INSERT 6453-2
2 - FRONT RETAINER
3 - JAWS 6453-1
Fig. 23 Bearing Cup Puller
1 - WRENCH
2 - INSERT 6453-2
3 - FRONT RETAINER
4 - PULLER 6444
5 - WRENCH
BR/BEMANUAL - NV4500 21 - 9
MANUAL - NV4500 (Continued)

DRIVE GEAR
(1) Remove drive gear (Fig. 24).
(2) Remove pilot bearing from drive gear (Fig. 25).(3) Remove tapered bearing from drive gear with
Puller Flange 6444-1 and Puller Rods 6444-6 (Fig.
26). Then position first Puller Jaw 6447 on bearing
(4) Slide assembled puller flange and rod tools
onto input shaft. Then seat flange in notch of puller
jaw.
(5) Position second Puller Jaw 6447 on gear and in
notch of puller flange.
(6) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place.
(7) Install Puller 6444 on puller rods then install
retaining nuts.
(8) Tighten puller bolt to remove bearing cone
from drive gear.
Fig. 24 Drive Gear
1 - MAINSHAFT
2 - DRIVE GEAR
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
21 - 10 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.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
30).
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
Fig. 29 Mainshaft And Geartrain
1 - MAINSHAFT AND CASE
Fig. 30 Countershaft Rear Bearing Plate
1 - REAR BEARING PLATE
2 - COUNTERSHAFT
BR/BEMANUAL - NV4500 21 - 11
MANUAL - NV4500 (Continued)

(2) Remove countershaft end play shim and rear
bearing cup (Fig. 31).
(3) Remove reverse idler shaft (Fig. 32).
(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 33).
(5) Remove idler gear (Fig. 34).
(6) Keep reverse idler gear bearings and spacer
together (Fig. 35). Insert idler shaft through gear and
bearings to keep them in place.
Fig. 31 Countershaft End Play Shim And Rear
Bearing Cup
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
Fig. 32 Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
Fig. 33 Idler Gear Moved Away From Countershaft
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT
Fig. 34 Reverse Idler Gear
1 - REVERSE IDLER GEAR
2 - DRIVE GEAR BORE
Fig. 35 Idler Gear Components
1 - BEARINGS
2 - REVERSE IDLER GEAR
21 - 12 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(7) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them
together for cleaning and inspection.
(8) To remove countershaft rear bearing ,assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
36).
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.
(9) Position first Puller Jaw 6449 on bearing cone
(10) Seat puller flange in notch of puller jaw just
installed on bearing cone
(11) Install second Puller Jaw 6449 on bearing and
in notch of puller flange
(12) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(13) Install Puller 6444 on puller rods, then secure
puller to rods with retaining nuts
(14) Tighten puller bolt to remove bearing from
shaft. If bearing is exceptionally tight, tap end of
puller bolt with copper mallet to help loosen bearing.
(15) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 37).
(16) ToRemove countershaft front bearing, assem-
ble Puller Flange 6444-1 and Puller Bolts 6444-4
(Fig. 38).
(17) Position first Puller Jaw 6451 on bearing.
(18) Seat puller flange in notch of puller jaw.
(19) Install second Puller Jaw 6451 on bearing and
in notch of puller flange.(20) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(21) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts
(22) Tighten puller bolt to remove bearing from
shaft. If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(23) Remove bearing puller tools.
Fig. 36 Countershaft Rear Bearing
1 - COLLAR 6444-8
2 - JAWS 6449
3 - PULLER 6444
4 - WRENCH
Fig. 37 Countershaft And Case
1 - COUNTERSHAFT
Fig. 38 Countershaft Front Bearing
1 - JAWS 6451
2 - COLLAR 6444-8
3 - PULLER 6444
4 - FLANGE 6444-1
BR/BEMANUAL - NV4500 21 - 13
MANUAL - NV4500 (Continued)

GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 39).
(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: Gear and synchro components can be
installed backwards. Paint or scriber gear and syn-
chro components for installation reference. Then
stack geartrain parts in order of removal.
(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).
(3) Remove third gear bearing from mainshaft
(Fig. 43).
(4) Remove third gear bearing spacer (Fig. 44).
(5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 44).
Fig. 39 Countershaft Front Bearing Cap
1 - HAMMER
2 - BEARING CAP
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
21 - 14 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(6) Remove second gear thrust washer (Fig. 45).
Note washer notch for locating pin.
(7) Remove thrust washer locating pin (Fig. 46)
with needle nose pliers.
(8) Remove second gear (Fig. 47).
(9) Remove second gear bearing (Fig. 48).
Fig. 42 Third Gear, Stop Ring, And 3-4 Hub
1 - THIRD GEAR
2 - THIRD GEAR STOP RING
3 - 3-4 SYNCHRO HUB
Fig. 43 Third Gear Bearing
1 - THIRD GEAR NEEDLE BEARING
Fig. 44 Snap Ring And Third Gear Bearing Spacer
1 - SECOND GEAR THRUST WASHER
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
Fig. 45 Second Gear Thrust Washer
1 - SECOND GEAR
2 - THRUST WASHER
3 - SECOND GEAR BEARING
BR/BEMANUAL - NV4500 21 - 15
MANUAL - NV4500 (Continued)

(10) Remove second gear clutch cone snap ring
from mainshaft synchro hub groove (Fig. 49).
(11) Remove second gear clutch cone, synchro
clutch ring and synchro stop ring (Fig. 50).
(12) Remove 1-2 synchro hub snap ring (Fig. 51).
(13) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 52). Note tapered side of
sleeve also goes toward front. Do not disassemble
synchro components unless worn or damaged.
(14) Remove first gear synchro stop ring and
clutch ring (Fig. 53).
Fig. 46 Thrust Washer Locating Pin
1 - THRUST WASHER LOCATING PIN
Fig. 47 Second Gear
1 - SECOND GEAR
Fig. 48 Second Gear Bearing
1 - SECOND GEAR NEEDLE BEARING
Fig. 49 Second Gear Clutch Cone Snap Ring
1 - 1-2 SLEEVE
2 - SNAP RING
3 - SECOND GEAR CLUTCH CONE
Fig. 50 Second Gear Clutch Cone And Ring
1 - 1-2 SLEEVE AND HUB
2 - SYNCHRO STOP RING
3 - CLUTCH RING
4 - SECOND GEAR CLUTCH CONE
21 - 16 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(15) Remove first gear clutch cone front snap ring
from mainshaft hub (Fig. 54).
(16) Remove first gear clutch cone (Fig. 55).
(17) Remove first gear clutch gear rear snap ring
from mainshaft hub (Fig. 55). Do not remove this
snap ring unless mainshaft is to be replaced.
(18) To remove mainshaft rear bearing, assemble
Puller Flange 6444-1 and Puller Rods 6444-3 for 4X2
or 6444-4 for 4X4 (Fig. 56).
(19) Position the first Puller Jaw 6445 on the bear-
ing cone.
(20) Seat Puller Flange 6444-1 in notch of first
puller jaw.
(21) Install the second Puller Jaw 6445 on the
bearing cone and puller flange.
Fig. 51 1-2 Sleeve And Hub Snap Ring
1 - 1-2 HUB SNAP RING
2 - 1-2 SLEEVE AND HUB
Fig. 52 1-2 Synchro Sleeve And Hub
1 - 1-2 SLEEVE AND HUB
Fig. 53 First Gear Stop And Clutch Ring
1 - FIRST GEAR CLUTCH RING
2 - FIRST GEAR STOP RING
Fig. 54 First Gear Clutch Gear Front Snap Ring
1 - FIRST SPEED CLUTCH GEAR
2 - CLUTCH GEAR SNAP RING (FRONT)
Fig. 55 First Gear Clutch Gear
1 - CLUTCH GEAR SNAP RING (REAR)
2 - FIRST SPEED CLUTCH GEAR
BR/BEMANUAL - NV4500 21 - 17
MANUAL - NV4500 (Continued)