Oss DODGE RAM 2003 Service Repair Manual

(2) Remove extension/adapter housing (Fig. 9).
There is one alignment dowel in the gear case and
one in the extension/adapter housing.
(3) Remove rubber spline seal from end of main-
shaft (Fig. 10). The seal is used to prevent lubricant
loss during shipping and does not have to be replaced
if damaged.
FIFTH GEAR NUT
(1) Remove extension/adapter housing.
(2) Loosen fifth gear clamp nut clamping screw
approximately 1 1/2 turns.
(3) Install Wrench 6743 on fifth gear nut (Fig. 11).
NOTE: Wrench only fits one way on nut. Make sure
wrench is fully engaged in nut slots and is not
cocked.
(4)
Install Socket 6993 4X2 or Socket 6984 4X4 with
breaker bar to hold mainshaft and remove fifth gear nut.
NOTE: Wedge breaker bar handle against workbench.
Purpose of socket wrench and breaker bar is to pre-
vent mainshaft from turning while nut is loosened.
(5) Remove fifth gear nut, then remove belleville
washer from mainshaft.
FIFTH GEAR
(1) Remove fifth gear shift fork roll pins (Fig. 12).
Drive roll pins out from the bottom of fork.
Fig. 9 EXTENSION/ADAPTER HOUSING
1 - GEAR CASE
2 - EXTENSION HOUSING
Fig. 10 MAINSHAFT SPLINE SEAL
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 11 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SPLINE SOCKET
Fig. 12 FIFTH GEAR SHIFT FORK ROLL PINS
1 - ROLL PINS
2 - FIFTH GEAR SHIFT FORK
21 - 46 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

the alignment dowels in the case top surface and in
the housing/adapter are tight and in good condition.
Replace the gear case or housing/adapter if cracked
or broken.
ASSEMBLY
NOTE: Gaskets are not used in the transmission.
Use Mopar Silicone Sealer or equivalent on all gear
case and extension housing sealing surfaces.
COUNTERSHAFT AND REVERSE IDLER GEAR
(1) Install countershaft front bearing cup in case
with Handle C-4171 and Installer 6061-1.
(2) Install front bearing on countershaft with
Installer C-4340 (Fig. 66).
(3) Lubricate countershaft front bearing cup and
cone with petroleum jelly.
(4) Position gear case on end with rear of case fac-
ing up (Fig. 67).
(5) Install countershaft in gear case (Fig. 67).
NOTE: Do not install rear countershaft bearing on
countershaft at this time.(6) Lubricate reverse idler gear bearings with
petroleum jelly and install first bearing and second
bearing (Fig. 68).
(7) Install idler gear front thrust washer on boss
in gear case (Fig. 68). Coat thrust washer with lib-
eral quantity of petroleum jelly to hold it in place.
Fig. 66 COUNTERSHAFT FRONT BEARING
1 - FRONT BEARING
2 - INSTALLER
3 - COUNTERSHAFT
Fig. 67 COUNTERSHAFT IN GEAR CASE
1 - GEAR CASE
2 - COUNTERSHAFT
Fig. 68 IDLER GEAR FRONT THRUST WASHER
1 - IDLER GEAR FRONT THRUST WASHER ON BOSS
DRMANUAL TRANSMISSION - NV4500 21 - 61
MANUAL TRANSMISSION - NV4500 (Continued)

(8) Install reverse idler gear in case (Fig. 69).
(9) Install idler gear rear thrust washer between
idler gear and case boss (Fig. 69).
(10) Align idler gear bearings and thrust washers
with a drift.
(11) Install reverse idler shaft with notched end of
shaft facing countershaft (Fig. 70).
(12) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 71).
(13) Install rear bearing cone on countershaft with
Installer C-4040 (Fig. 72).
(14) Remove wood block from under countershaft
and lower countershaft front bearing into front bear-
ing cup.(15) Lubricate countershaft rear bearing cup and
cone with petroleum jelly.
(16) Install countershaft rear bearing cup in gear
case and over rear bearing (Fig. 73). Tap cup into
place with plastic mallet if necessary.
(17) Install countershaft rear bearing plate (Fig.
74).
NOTE: Verify plate is seated in notch in reverse
idler shaft before tightening bearing plate bolts.
Fig. 69 IDLER GEAR
1 - REAR THRUST WASHER
2 - REVERSE IDLER GEAR
3 - FRONT THRUST WASHER
Fig. 70 REVERSE IDLER SHAFT
1 - COUNTERSHAFT
2 - SHAFT NOTCH
3 - REVERSE IDLER SHAFT
Fig. 71 SUPPORTING COUNTERSHAFT
1 - COUNTERSHAFT
2 - WOOD BLOCK
Fig. 72 COUNTERSHAFT REAR BEARING
1 - INSTALLER
2 - REAR BEARING
3 - COUNTERSHAFT
21 - 62 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(8) Assemble and install fifth synchro clutch gear
and stop ring in fifth gear hub (Fig. 125). Verify
parts are seated in fifth gear hub.
(9) Install clutch gear snap ring (Fig. 126).
(10) Align roll pin holes in shift fork with notches
in shift lug rail. Then install roll pins from top side
of fork (Fig. 123).
NOTE: Roll pins only fit one way due to small
shoulder at one end of each pin.
FIFTH GEAR NUT
(1) Install belleville washer onto the mainshaft.
(2) Install fifth gear nut over the mainshaft.
(3) Tighten the clamp bolt until the gap in the
clamp nut assembly is closed.
(4) Back the clamp bolt off one full turn.(5) Place 10-15 drops of Loctite 272 onto the main-
shaft threads where the fifth gear nut will be
engaged.
(6) Install fifth gear nut on mainshaft (Fig. 127).
(7) Hold mainshaft Socket 6993 4X2 or Socket
6984 4X4 while installing the fifth gear nut.
(8) Tighten fifth gear nut as much as possible with
Wrench 6743, long handle ratchet, breaker bar and
applicable socket wrench (Fig. 128).
(9) Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
Fig. 125 FIFTH SYNCHRO CLUTCH GEAR AND
STOP RING
1 - STOP RING
2 - CLUTCH GEAR
Fig. 126 FIFTH SYNCHRO CLUTCH SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
Fig. 127 FIFTH GEAR NUT
1 - FIFTH GEAR
2 - FIFTH GEAR NUT
Fig. 128 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SOCKET
21 - 76 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

²release fork ball stud.
²propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
(4) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start input
shaft in release bearing, clutch disc and pilot bush-
ing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install transmission bolts and tighten to 108
N´m (80 ft. lbs.).
(8) Install transmission mount on transmission or
rear crossmember.
(9) Install rear crossmember.
(10) Remove transmission jack and engine support
fixture.
(11) Position transmission harness wires in clips
on shift cover.
(12) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(13) 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 transfer case nuts and tighten to:
²If 3/8 studs 41-47 N´m (30-35 ft. lbs.).
²If 5/16 studs 30-41 N´m (22-30 ft. lbs.).
(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.).
(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.
(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.
21 - 78 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(2) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(3) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(4) Remove the shift tower and isolator plate from
the transmission gear case.
(5) Raise and support vehicle.
(6) Remove skid plate, if equipped.
(7) Mark propeller shaft/shafts and axle yokes for
installation reference.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system as nec-
essary.
(10) Disconnect wires at backup light switch.
(11) Support engine with adjustable safety stand
and wood block.
(12) If transmission is to be disassembled for
repair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission (Fig. 3).
(13) Remove clutch slave cylinder splash shield, if
equipped.
(14) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(15)
Remove wire harness from clips on transmission.
TWO WHEEL DRIVE
(1) Remove bolts/nuts mounting transmission to
the rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmember.
(4) Remove transmission clutch housing bolts at
the engine block.
(5) Slide transmission and jack rearward until
input shaft clears clutch disc and pressure plate.
(6) 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.
(2) Support and secure transfer case with safety
chains to a transmission jack.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(8) Remove rear crossmember bolts and pry out
crossmember.
(9) Remove transmission clutch housing bolts at
the engine block.
(10) Move transmission rearward until input shaft
clears clutch disc.
(11) Lower transmission and remove it from under
vehicle.
DISASSEMBLY
NOTE: Use Fixture 8241 for moving and handling
the transmission. The fixture supports the transmis-
sion at the center of gravity in order to ease mount-
ing the transmission into the build fixture.
(1)
Mount the transmission into Fixture 8230 (Fig. 4).
Fig. 3 NV5600 DRAIN BOLT
1 - PTO COVER
2 - DRAIN BOLT
Fig. 4 TRANSMISSION FIXTURE
1 - FIXTURE
2 - TRANSMISSION
21 - 90 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

(3) Remove crossover detent plug, spring and
plunger from the extension/adapter housing (Fig. 13).
(4) Remove bolt and washer holding the crossover
cam to the extension/adapter housing (Fig. 14).
(5) Remove crossover cam from the extension/
adapter housing.
(6) Remove back-up lamp switch from the exten-
sion/adapter housing.
(7) Remove countershaft rear bearing race from
the extension/adapter housing with Remover L-4518
(Fig. 15).NOTE: Tag all countershaft pre-load shims from
between the bearing race and the housing (Fig. 16).
(8) Remove crossover cam bushing from the exten-
sion/adapter housing with Remover 8240.
(9) On 4X2 vehicles, remove extension housing
seal with a pry tool or a slide hammer and screw.
(10) On 4X4 vehicles, remove adapter housing seal
with a pry tool or a slide hammer and screw.
Fig. 13 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
Fig. 14 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
Fig. 15 COUNTERSHAFT REAR BEARING RACE
1 - REMOVER
Fig. 16 COUNTERSHAFT REAR BEARING RACE
AND SHIM
1 - PRE-LOAD SHIM
2 - BEARING RACE
DRMANUAL TRANSMISSION - NV5600 21 - 93
MANUAL TRANSMISSION - NV5600 (Continued)

REVERSE GEAR
(1) Remove crossover cam rollers and pin (Fig. 17).
(2) Remove reverse idler thrust washer from the
reverse idler.
(3) Remove reverse idler and reverse countershaft
gears together (Fig. 18).(4) Remove reverse idler gear rear bearing, bear-
ing spacer, front bearing and front thrust washer
from the idler gear shaft.
(5) Remove reverse countershaft rear bearing from
the countershaft reverse gear assembly with Puller
C-293-PA and Adapters C-293-52 (Fig. 19).
(6) Seperate countershaft reverse gear and sleeve.
(7) Remove output shaft nut with Wrench 8226 on
the shaft nut and Socket 6993 or 6984 to hold the
shaft (Fig. 20). Discard output shaft nut from the
output shaft.
NOTE: If necessary strike the flat side area of
Wrench 8226 with a hammer to break the nut loose.
Fig. 17 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 18 REVERSE IDLER AND COUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 19 COUNTERSHAFT REAR BEARING PULLER
1 - PULLER
2 - ADAPTERS
Fig. 20 LOOSEN OUTPUT SHAFT NUT
1 - WRENCH
2 - SOCKET
21 - 94 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

(12) Remove reverse shift fork and synchronizer as
an assembly from the reverse shift rail and the out-
put shaft (Fig. 24).
TRANSMISSION GEAR CASE
(1) Remove remaining bolts holding the transmis-
sion gear case to the clutch housing.
(2) Remove the shift socket roll pin witha6mm
(7/32 in.) punch and hammer.
(3) Turn shift socket so it won't catch the case
when lifting it up.
(4) Install Fixture 8232 to the transmission gear
case.
(5) Attach an engine crane or equivalent to Fixture
8232 and remove the transmission gear case from the
clutch housing (Fig. 25).
(6) Remove rear output shaft and countershaft
bearing races from the transmission gear case with a
brass drift and hammer.
GEARTRAIN
(1) Remove bolts holding the 5-6 crossover bracket
to the clutch housing (Fig. 26).
Fig. 24 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 25 TRANSMISSION CASE LIFT FIXTURE
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 26 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKET
21 - 96 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

(2) Attach Fixture 8232 to the output shaft and
countershaft (Fig. 27).
(3) Attach an engine crane or equivalent to Fixture
8232 and raise the geartrain approximately 1/4 in.
from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
(5) Lower the geartrain back into the clutch hous-
ing.
(6) Install Holding Tool 8242 (Fig. 28) onto the 5-6
synchro and tighten the screw to hold the 5-6 syn-
chro together during the removal operation.
NOTE: Note the order of the shift fork arms at the
primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
(8) Remove shift rails from the rest of the
geartrain (Fig. 29).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig. 27 FIXTURE/OUTPUT SHAFT
1 - OUTPUT SHAFT
2 - FIXTURE
Fig. 28 Remove Holding Tool
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 29 SHIFT RAILS
1 - 5-6 SHIFT RAIL
DRMANUAL TRANSMISSION - NV5600 21 - 97
MANUAL TRANSMISSION - NV5600 (Continued)