Oss DODGE RAM 2003 Service Repair Manual

(6) Install Fixture 8232 to the output shaft and
countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5-6 synchro
together during the remainder of the installation pro-
cedure.
(8) Attach a engine crane or equivalent to Fixture
8232 and move the geartrain from the Support Stand
8246 to the clutch housing (Fig. 79).
(9) Install shift forks and rails onto the geartrain
(Fig. 80).
NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) Install geartrain and shift rails into the clutch
housing. Lower the geartrain and rails into the hous-
ing slowly while guiding input shaft through input
shaft seal. Avoid any binds on the shift rails, forks
and synchros as the rails enter their bushings.
CAUTION: Do not damage input shaft seal with the
input shaft splines.(11) With the geartrain approximately 1/4 in. from
the clutch housing, remove Holding Tool 8242 from
the 5-6 synchro (Fig. 81).
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.
Fig. 79 GEARTRAIN FIXTURE
1 - FIXTURE
2 - SUPPORT STAND
Fig. 80 SHIFT RAILS INSTALLED
1 - SHIFT RAILS
Fig. 81 HOLDING TOOL
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
DRMANUAL TRANSMISSION - NV5600 21 - 115
MANUAL TRANSMISSION - NV5600 (Continued)

(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts and
tighten to 28 N´m (20 ft. lbs.) (Fig. 82).
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
TRANSMISSION GEAR CASE
(1) Install rear output shaft bearing race into the
transmission gear case with Installer C-4308 and
Handle C-4171.
(2) Install rear countershaft bearing race into the
transmission gear case with Installer 8153 and Han-
dle C-4171.
(3) Install Fixture 8232 to the transmission gear
case.
NOTE: Shift socket must be loose on the shift shaft
and is rotated a minimum of 90É from its normal
position. This will ensure enough clearance to
install the transmission gear case.
(4) Apply sealant to the clutch housing.
(5) Attach an engine crane or equivalent to Fixture
8232 and install the transmission gear case onto the
clutch housing (Fig. 83).
(6) Install clutch housing bolts and tighten to 48
N´m (35 ft.lbs.).
(7) Install shift socket roll pin with a suitable 6
mm (7/32 in.) punch and hammer.
MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use
Socket 6993 to rotate the shafts and seat the bear-
ings.
(2) Measure mainshaft endplay with Dial Indicator
Set C-3339 and Extension Rod 8161 installed onto
the rear of the transmission gear case (Fig. 84).
Fig. 82 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKETFig. 83 LIFT FIXTURE
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 84 MEASURE MAINSHAFT ENDPLAY
1 - DIAL INDICATOR
2 - EXTENSION ROD
3 - MAIN SHAFT
21 - 116 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171, if necessary. The
oil feed hole must be at the 12 o'clock position when
installed.
(2) On 4X2 vehicles, install extension housing seal
with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 93).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.(12)
The difference between the two measurements is
the end-play for the reverse countershaft gear assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.006-
0.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
Fig. 91 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 92 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
Fig. 93 MEASURE DEPTH OF REVERSE
COUNTERSHAFT GEAR BEARING RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
DRMANUAL TRANSMISSION - NV5600 21 - 119
MANUAL TRANSMISSION - NV5600 (Continued)

(14) Use Installer to install the reverse counter-
shaft bearing race into the extension/adapter hous-
ing.
(15) Install back-up lamp switch into the exten-
sion/adapter housing and tighten to 28 N´m (20
ft.lbs.).
(16) Install crossover cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 94).
(18) Install crossover detent plunger, spring and
plug into the extension/adapter housing. Tighten the
plug to 47.5 N´m (35 ft.lbs.) (Fig. 95).
(19) Apply sealer to the surface of the transmis-
sion case.(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter
housing onto the transmission gear case. Tighten
bolts to 48 N´m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N´m (41 ft.lbs.).
(23) Install primary shift rail detent plunger,
spring and plug into the transmission case. Tighten
detent plug to 47.5 N´m (35 ft.lbs.).
(24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com-
ponents supplied with the transmission. If a new
shift tower is supplied with the new transmission,
do not re-use the original shift tower.
(1) Apply a light coat of Mopar high temperature
bearing grease or equivalent 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.
(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 clutch disc hub.
(5) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(6) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-engine
block bolts.
(8) Install clutch slave cylinder.
(9) Connect backup light switch wires.
(10) Position transmission harness wires in clips
on transmission.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Fill transmission with required lubricant (Fig.
96). Check lubricant level in transfer case if
equipped.
Fig. 94 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
Fig. 95 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
21 - 120 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify shift tower, isolator plate and the shift
socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso-
lator plate and the transmission case. Tighten bolts
to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(11) Install shift boot and bezel.
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
(3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts
to 41-47 N´m (30-35 ft. lbs.) if case has 3/8 studs. If
case has 5/16 studs tighten to 30-41 N´m (22-30 ft.
lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.
(6) Install propeller shafts with reference marks
aligned.
(7) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(8) Install exhaust system components.
(9) Remove support and lower vehicle.
(10) Shift transmission into third gear.
(11) Clean the mating surfaces of shift tower, iso-
lator plate and transmission case with suitable wax
and grease remover.
(12) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission case. Do not
over apply sealant.
(13) Install isolator plate onto the transmission
case, metal side down.
(14) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(15) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(16) Install the bolts to hold the shift tower to the
isolator plate and the transmission case. Tighten the
shift tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(17) Install shift lever boot and bezel.
Fig. 96 FILL PLUG
1 - FILL PLUG
DRMANUAL TRANSMISSION - NV5600 21 - 121
MANUAL TRANSMISSION - NV5600 (Continued)

SPECIFICATIONS - NV5600
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Crossover Cam and Detent 48 35 -
Bolt, Input Retainer 28 20 -
Bolt, 5-6 Crossover Bracket 28 20 -
Bolt, Clutch Housing 48 35 -
Bolt, Extension/Adapter Housing 48 35 -
Bolt, Shift Tower 9 7 80
Switch, Back-up Lamp 28 20 -
Bolt, Shift Blocker 55 41 -
Bolt, PTO Cover 40 30 -
Pivot, Clutch Release Lever 22 16 -
Plug, Fill 30 22 -
Nut, Output Shaft 339 250 -
SPECIAL TOOLS
REMOVER 8155
INSTALLER 8156
HANDLE C-4171
INSTALLER C-3972-A
INSTALLER 8154
21 - 122 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
²Leaks at the weld joint around the outside diam-
eter weld.
²Leaks at the converter hub weld.
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Tighten front band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out when oil pump is
removed.
(3) Remove oil pump and remove pump seal.
Inspect pump housing drainback and vent holes for
obstructions. Clear holes with solvent and wire.
(4) Inspect pump bushing and converter hub. If
bushing is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
converter.
(5) Install new pump seal, O-ring, and gasket.
Replace oil pump if cracked, porous or damaged in
any way. Be sure to loosen the front band before
installing the oil pump, damage to the oil pump seal
may occur if the band is still tightened to the front
clutch retainer.
(6) Loosen kickdown lever pin access plug three
turns. Apply LoctiteŸ 592, or PermatextNo.2toplug threads and tighten plug to 17 N´m (150 in. lbs.)
torque.
(7) Adjust front band.
(8) Lubricate pump seal and converter hub with
transmission fluid or petroleum jelly and install con-
verter.
(9) Install transmission and converter housing
dust shield.
(10) Lower vehicle.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The diagnosis charts provide additional reference
when diagnosing a transmission fault. The charts
provide general information on a variety of transmis-
sion, overdrive unit and converter clutch fault condi-
tions.
The hydraulic flow charts in the Schematics and
Diagrams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
PARK, NEUTRAL, FIRST, SECOND, THIRD,
FOURTH, MANUAL FIRST, MANUAL SECOND,
and REVERSE gear ranges. Normal working pres-
sures are also supplied for each of the gear ranges.
21 - 144 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

DIAGNOSIS CHARTS
CONDITION POSSIBLE CAUSES CORRECTION
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)1. Fluid Level Low. 1. Add Fluid
2. Throttle Linkage Mis-adjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Mis-adjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component damaged.10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty. 11. Replace converter.
DELAYED ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Mis-adjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Torque Converter Drain Back (Oil
drains from torque converter into
transmission sump).4. If vehicle moves normally after 5
seconds after shifting into gear, no repair is
necessary. If longer, inspect pump bushing
for wear. Replace pump house.
5. Rear Band Mis-adjusted. 5. Adjust band.
6. Valve Body Filter Plugged. 6. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
7. Oil Pump Gears Worn/Damaged. 7. Remove transmission and replace oil
pump.
8. Governor Circuit and Solenoid
Valve Electrical Fault.8. Test with DRBTscan tool and repair as
required.
9. Hydraulic Pressure Incorrect. 9. Perform pressure test, remove
transmission and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.10. Remove transmission, remove oil pump
and replace seal rings.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.11. Remove and disassemble transmission
and repair as necessary.
12. Regulator Valve Stuck. 12. Clean.
13. Cooler Plugged. 13. Replace cooler.
DRAUTOMATIC TRANSMISSION - 46RE 21 - 145
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO DRIVE RANGE
(REVERSE OK)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Replace
cooler as necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body. Replace
valve body (as assembly) if any valve or
bore is damaged. Clean and reassemble
correctly if all parts are in good condition.
7. Transmission Internal Component
Damaged.7. Remove and disassemble transmission.
Repair or replace failed components as
needed.
8. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
21 - 146 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return
to closed throttle at transmission.
5. Gearshift Linkage/Cable
Mis-adjusted.5. Adjust linkage/cable as described in
service section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
7. Governor Circuit Electrical Fault. 7. Test using DRBTscan tool and repair as
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)1. Gearshift Linkage/Cable
Mis-adjusted/Damaged.1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)1. Governor Circuit Electrical Fault. 1. Test using DRBTscan tool and repair as
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor
plug.
3. Front Servo/Kickdown Band
Damaged/Burned.3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
DRAUTOMATIC TRANSMISSION - 46RE 21 - 147
AUTOMATIC TRANSMISSION - 46RE (Continued)