DODGE RAM 2002 Service Repair Manual

(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
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
Bolts27-34 20-25 235-305
Mainshaft Bearing Plate
Bolts19-26 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
Remover Seal C-3985-B
Remover Bushing 6957
Remover, BushingÐ8155
Installer Bushing 6951
21 - 38 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

Installer Bushing 8156
Handle C-4171
Installer Seal C-3972-A
Installer Seal 8154
Installer Seal C-3860-A
Wrench 6443
Wrench 6743
Socket 6441
Socket 6442
Socket 6993
BR/BEMANUAL - NV4500 21 - 39
MANUAL - NV4500 (Continued)

Socket 6984
Puller 6444
Jaws 6459
Jaws 6820
Jaws and Insert 6453
Jaws 6447
Jaws 6449
Jaws 6451
Remover 6454
21 - 40 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

Installer 6061
Installer C-4340
Installer C-4040
Installer 6448
Installer C-4308
Installer 6052
Rod Extension 8161
Installer 6446
Jaws 6445
BR/BEMANUAL - NV4500 21 - 41
MANUAL - NV4500 (Continued)

ADAPTER HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support vehicle.
(2) Mark the propeller shafts and yokes for instal-
lation reference and remove the shafts.
(3) Support transmission with a transmission jack.
(4) Remove engine rear support.
(5) Remove transfer case.
(6) Remove adapter housing seal with a pry tool or
slide hammer mounted screw (Fig. 128).
INSTALLATION
(1) Install adapter housing seal with Installer
C-3860-A and Handle C-4171.
(2) Install transfer case.
(3) Install propeller shafts with reference marks
aligned.
(4) Fill transfer case and transmission to proper
level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the propeller shaft and yoke for installa-
tion reference.
(3) Remove the propeller shaft.
(4) Remove extension housing seal (Fig. 129) using
Remover C-3985-B.(5) On heavy duty 4X2 vehicles, remove extension
housing seal with a pry tool or a slide hammer
mounted screw.
(6) On light duty transmissions, remove the exten-
sion housing bushing with Remover 6957.
(7) On heavy duty transmissions, remove the
extension housing bushing with Remover 8155.
INSTALLATION
(1) Install housing bushing with Handle C-4171
(Fig. 130) and Installer.
²Light Duty - Installer 6951
²Heavy Duty - Installer 8161
(2) Install housing seal with Handle C-4171 (Fig.
131) and Installer.
²Light Duty - Installer C-3972-A
²Heavy Duty - Installer 8154
(3) Install propeller shaft with reference marks
aligned.
Fig. 128 Adapter Housing - 4WD
1 - ADAPTER HOUSING
2 - SEAL
Fig. 129 Extension Housing - 2WD
1 - EXTENSION HOUSING
2 - SEAL
Fig. 130 Extension Housing Bushing
1 - HANDLE C-4171
2 - INSTALLER
3 - EXTENSION HOUSING
21 - 42 MANUAL - NV4500BR/BE

(4) Check and fill transmission.
(5) Remove support and lower vehicle.
SHIFT MECHANISM - NV4500
REMOVAL
(1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 132).
(3) Pry up shift cover at slots provided in cover
(Fig. 133).
(4) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 134).
(5) Raise front of shift cover and lift cover up and
off gear case (Fig. 134).
FIFTH-REVERSE SHIFT FORK PADS
Three shift pads on the forks are held in place by
tension and a small locating tang (Fig. 135).
To remove the pads, grasp a pad with hand and tilt
it out and off the fork. If pad is difficult to remove by
hand, insert a screwdriver blade between the pad
and fork and pry the pad off.
EXPANSION PLUG
The expansion plugs at the rear of the shift rail
bores (Fig. 136) can be replaced if loose/leaking.
(1) Drill 6 mm (1/4 in.) diameter hole in center of
the plug to be removed.
(2) Pry plug out of cover with tapered punch.
Fig. 131 Extension Housing Seal
1 - HANDLE C-4171
2 - INSTALLER
Fig. 132 Shift Cover Bolts
1 - SHIFT COVER
2 - BOLTS
Fig. 133 Loosening Shift Cover
1 - SHIFT COVER SLOT
2-PRYTOOL
Fig. 134 Shift Cover
1 - SHIFT COVER
2 - ALIGNMENT DOWELS
BR/BEMANUAL - NV4500 21 - 43
EXTENSION HOUSING SEAL - NV4500 (Continued)

(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of Mopar silicone sealer or
equivalent to outer edge of each new plug.
(2) Position each plug in bore and tap into place
with hammer and punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab.
(2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift cover and gear
case with wax and grease remover.(2) Apply a small amount of Mopar silicone sealer
or equivalent to sealing surface of shift cover.
CAUTION: Do not over-apply an excesive amount
sealer. Excess can squeezed into gear case and
could block lubricant feed holes in time.
(3) Lubricate synchro sleeves with CastroltSyn-
torq gear lubricant or equivalent. Then apply light
coat of petroleum jelly to shift fork contact surfaces.
(4) Verify shift fork pads (Fig. 137) are secure.
(5) Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
(6) Align and seat shift cover on transmission.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
(7) Apply Mopar Lock N' Seal or equivalent to
threads of shift cover bolts.
(8) Install shift cover bolts and tighten to 27-31
N´m (216-276 in. lbs.).
(9) Apply sealer to backup lamp switch. Install
switch into cover and tighten to 22-34 N´m (193-265
in. lbs.).
(10) Install vent assembly if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
(11) Install transmission.
Fig. 135 Shift Fork Pad Locations
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
Fig. 136 Expansion Plug Location
1 - EXPANSION PLUGS
Fig. 137 Fifth-Reverse Shift Fork Pads
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
21 - 44 MANUAL - NV4500BR/BE
SHIFT MECHANISM - NV4500 (Continued)

SHIFT COVER - NV4500
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 Mopar Gasket 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 shift tower, isolator plate and shift tower
bushings are properly aligned.
(6) Install bolts to hold the shift tower to the iso-
lator 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 shift lever extension, shift boot and
bezel.
BR/BEMANUAL - NV4500 21 - 45

MANUAL - NV5600
TABLE OF CONTENTS
page page
MANUAL - NV5600
DESCRIPTION.........................46
OPERATION...........................48
DIAGNOSIS AND TESTING................48
REMOVAL.............................49
DISASSEMBLY.........................49
CLEANING............................63
INSPECTION..........................63
ASSEMBLY............................64
INSTALLATION.........................78
SPECIFICATIONS.......................79SPECIAL TOOLS......................80
ADAPTER HOUSING SEAL - NV5600
REMOVAL.............................85
INSTALLATION.........................85
EXTENSION HOUSING SEAL - NV5600
REMOVAL.............................85
INSTALLATION.........................85
SHIFT COVER - NV5600
REMOVAL.............................86
INSTALLATION.........................86
MANUAL - NV5600
DESCRIPTION
The NV5600 is a six speed constant mesh manual
transmission (Fig. 1). All gear ranges including
reverse are synchronized. First and second gears uti-
lize dual cone synchronizers in order to aid shifting.
Sixth gear is an overdrive range. The transmission
uses cast iron for the gear case and extension/
adapter housing and aluminum for the clutch hous-
ing.
To drain the trans remove the bottom PTO cover
bolt. Fill the trans through the plug to the rear of the
PTO cover (Fig. 1). Dry fill is approximately 4.5 liters
(9.5 pints) or to the bottom edge of the fill plug hole.
The transmission is a end loader transmission. The
shift lever is located in a shifter tower which is
bolted to the gear case and operates the shift shaft.
The shift pattern is in a modified H pattern (Fig.
2). Overdrive fifth and sixth gears are in line and
outboard of the first through fourth gear positions.
Reverse gear is to the right of fifth and sixth and for-
ward of the neutral gate.The gear ratios are:
GEAR RATIOS
GEAR RATIO
FIRST 5.63:1
SECOND 3.38:1
THIRD 2.04:1
FOURTH 1.39:1
FIFTH 1.00:1
SIXTH 0.73:1
REVERSE 5.63:1
IDENTIFICATION
The transmission has two identification tags
attached to the driver side upper clutch housing (Fig.
3). One tag provides the transmission part number.
The second tag provides sequencing and build date
information. The information on the tags are essen-
tial to correct parts ordering.
21 - 46 MANUAL - NV5600BR/BE

Fig. 1 NV5600 Manual Transmission
BR/BEMANUAL - NV5600 21 - 47
MANUAL - NV5600 (Continued)