Rear seat DODGE RAM 1500 1998 2.G Workshop Manual

Inspect output shaft bearing retainer, the
U-shaped retainer must be flat and free of distortion.
Replace the retainer if the threads are damaged or if
the retainer is bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, the front or rear hous-
ing must be replaced. A new countershaft bearing
will be supplied with each new housing for service
use.
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing if any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted or brinnelled. Also
replace the bearing if the plastic bearing cage is
damaged or distorted.
Replace thrust washer, wave washer or thrust
plate if cracked, chipped or worn. Replace idler gear
if the teeth are chipped, cracked or worn thin.
Replace shaft if worn, scored or the bolt threads are
damaged beyond repair. Replace support segment if
cracked or chipped and replace the idler attaching
bolts if the threads are damaged.
Shift Socket
Inspect the shift socket for wear or damage.
Replace the socket if the roll pin or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn or cracked. Do not reuse the original
shift socket roll pin. Install anewpin during assem-
bly. The socket roll pin is approximately 33 mm
(1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro-
ken teeth. Also check condition of the bearing bore in
each gear. The bores should be smooth and free of
surface damage. Discoloration of the gear bores is a
normal occurrence and is not a reason for replace-
ment. Replace gears only when tooth damage has
occurred or if the bores are brinnelled or severely
scored.
Inspect the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-aged or bearing surfaces are deeply scored, worn or
brinnelled.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use
Mopar Gasket Maker or equivalent for all case joints
and Mopar silicone sealer or equivalent for the
input shaft bearing retainer.
SYNCHRONIZER
(1) Slide sleeve onto the hub, leaving enough room
to install the spring in the hub and strut in the hub
groove.
(2) Install first spring in the hub, then install a
strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide sleeve onto the hub far enough to hold
the first strut and spring in place.
(4) Place detent ball in the top of the strut, then
press the ball into place with a small screwdriver.
Work the sleeve over the ball to hold it in place.
(5) Repeat procedure for the remaining springs,
struts and balls. Use tape or rubber bands to tempo-
rarily secure each strut and ball as they are
installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 49).
Fig. 49 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
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MANUAL TRANSMISSION - NV3500 (Continued)

(28) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to
output shaft as possible but not contacting the
shaft splines.
(29) Installnew3-4 synchro hub snap ring (Fig.
75). Verify snap ring is seated in groove.(30) Install output shaft bearing.
(31) Install output shaft bearing snap ring with
heavy duty snap ring pliers (Fig. 76). Verify snap
ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
(32) Verify position of synchro sleeves before pro-
ceeding (Fig. 77). Grooved side of 3-4 sleeve must
face forward. First gear side of 1-2 sleeve must face
first gear. Tapered side of fifth-reverse sleeve must
face forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube.
(2) Slide idler gear bearing on shaft (Fig. 78).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 78).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 78). Petroleum jelly can be used to
hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 79).
(6) Install snap ring in groove at rear of shaft (Fig.
79).
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
Fig. 74 3-4 SYNCHRO ON OUTPUT SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 75 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 76 OUTPUT SHAFT BEARING SNAP
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
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MANUAL TRANSMISSION - NV3500 (Continued)

(8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 80).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 80). Verify snap
ring is seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/
BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
(2) If necessary, the shift shaft bushing can be
replaced as follows:
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.
(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case.
(3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case.
(4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive
the detent bushings through the outer case and
into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
the case.
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
Fig. 80 IDLER GEAR & SHAFT ASSEMBLY
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
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MANUAL TRANSMISSION - NV3500 (Continued)

(11) On 2-wheel drive transmission, thread one
Alignment Pin 8120 in center or passenger side hole
of output shaft bearing retainer. Then position
retainer on fifth gear as shown (Fig. 88).
(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
89). Arm of fifth-reverse fork goes through slot in 1-2
fork.
(13) Install assembled shift forks in synchro
sleeves and verify forks are seated in sleeves (Fig.
90).
REAR HOUSING - 2WD
NOTE: Transmission shift components must be in
Neutral position to prevent damaging the synchro
and shift components when installing the housings.(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 91).
Fig. 88 ALIGN OUTPUT SHAFT BEARING RETAINER
1 - ALIGNMENT PIN
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 89 1-2 & FIFTH-REVERSE SHIFT FORKS
1 - 1-2 FORK
2 - 1-2 FORK ARM
3 - FIFTH-REVERSE FORK
Fig. 90 SHIFT FORKS IN SYNCHRO
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
Fig. 91 REAR HOUSING DOWELS
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
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MANUAL TRANSMISSION - NV3500 (Continued)

(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 92).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(4) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 93).
(6) Reach into countershaft rear bearing with fin-
ger and push each bearing roller outward against the
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(7) Install rear housing onto geartrain (Fig. 94)
and verify bearing retainer pilot stud is in correct
bolt hole in housing. Verify countershaft and output
shaft bearings are aligned in housing and on counter-
shaft.
NOTE: It may be necessary to lift upward on coun-
tershaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
(8) Seat rear housing on output shaft rear bearing
and countershaft by tapping the housing with a plas-
tic mallet.
Fig. 92 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY
Fig. 93 COUNTERSHAFT BEARING
1 - SHIFT SHAFT BUSHING/BEARING
2 - COUNTERSHAFT REAR BEARING
Fig. 94 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
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MANUAL TRANSMISSION - NV3500 (Continued)

(9) Install rear bearing snap ring on output shaft
(Fig. 98).
(10) Lubricate lip of new rear seal (Fig. 99) with
Mopar Door Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 99).SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify all synchro sleeves are in Neutral posi-
tion (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position to prevent damaging the housings,
shift forks and gears while installing the housings.
(2) Install 3-4 shift fork in synchro sleeve (Fig.
100). Verify groove in fork arm is aligned with
grooves in 1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
101).
Fig. 98 REAR BEARING SNAP RING
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 99 ADAPTER HOUSING REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
Fig. 100 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 101 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
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MANUAL TRANSMISSION - NV3500 (Continued)

(2) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 113). Large diameter side of
bearing cage goes toward countershaft (Fig. 114).
Small diameter side goes toward bearing race in
housing.
(3) Reach into countershaft front bearing with fin-
ger and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
(5) Apply 1/8 in. wide bead of Mopar Gasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 115).
(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 Mopar Gasket Maker or equivalent to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 116).
(11) Install and start housing attaching bolts by
hand (Fig. 116). Then tighten bolts to 34 N´m (25 ft.
lbs.).
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 115 SEAL HOUSINGS
1 - HOUSING FLANGE SURFACE
2 -GASKET MAKER
Fig. 116 HOUSING BOLTS
1 - HOUSING BOLTS
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MANUAL TRANSMISSION - NV3500 (Continued)

INSTALLATION
NOTE: If a new transmission is being installed, use
all components supplied with the new transmission.
For example, if a new shift tower is supplied, do not
re-use the original shift tower.
(1) Clean transmission front housing mounting
surface.
(2) Apply light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces (Fig.
126) of following components:
²release fork ball stud.
²release bearing slide surface.
²input shaft splines.
²release bearing bore.
²propeller shaft slip yoke.
(3) Support and secure transmission to jack.
(4) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(5) Verify front housing is fully seated. Install
transmission bolts without washers and tighten bolts
into the engine to 41 N´m (30 ft. lbs.). Tighten the
bolts with washers into the transmission to 68 N´m
(50 ft. lbs.) (Fig. 127).(6) Install rear crossmember and tighten nuts to
102 N´m (75 ft. lbs.).
(7) Install transmission rear mounting bolts and
tighten to 68 N´m (50 ft. lbs.).
(8) Install front dust shield tighten bolt to 4.5 N´m
(40 in. lbs.). If cover was removed, install onto the
transmission and engine(Refer to 9 - ENGINE/EN-
GINE BLOCK/STRUCTURAL COVER - INSTALLA-
TION).
(9) Install structural dust cover and tighten the
bolts to 54 N´m (40 ft. lbs.).
(10) Install starter motor.
(11) Install suspension crossmember and tighten
nuts to 102 N´m (75 ft. lbs.).
(12) Connect transmission harnesses to clips on
case and connect switches.
(13) Install slave cylinder and tighten cylinder
nuts to 23 N´m (200 in. lbs.).
(14) Install transfer case and transfer case linkage
if equipped.
(15) Remove transmission jack.
(16) Install propeller shaft/shafts with reference
marks aligned.
(17) Install exhaust on the exhaust manifolds.
(18) Fill transmission with lubricant. Correct fill
level is to bottom edge of fill plug hole.
Fig. 126 LUBRICATION POINTS
1 - RELEASE FORK
2 - FORK BALL STUD
3 - BEARING SLIDE SURFACE
4 - SPLINE
5 - RELEASE BEAING
Fig. 127 TRANSMISSION
1 - BOLT WITHOUT WASHER
2 - BOLT WITH WASHER
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MANUAL TRANSMISSION - NV3500 (Continued)

(7) Remove countershaft fifth gear needle bearing
assembly (Fig. 13).
(8) Remove coned shape rear bearing thrust
washer from countershaft (Fig. 14).
NOTE: Note washer bore locating notch for assem-
bly reference.
(9) Remove thrust washer locating pin from coun-
tershaft.(10) Remove mainshaft fifth gear with Puller Set
6444 and Jaw 6459 or 6820. Position first Jaw on
gear (Fig. 15).
(11) Assemble Puller Flange 6444-1and Puller
Rods 6444-3 4X2 or 6444-4 4X4 (Fig. 16). Slide
assembly onto output shaft and seat flange in notch
of jaw.
Fig. 13 COUNTERSHAFT FIFTH GEAR NEEDLE
BEARING
1 - NEEDLE BEARING
2 - COUNTERSHAFT
Fig. 14 COUNTERSHAFT REAR BEARING THRUST
WASHER
1 - THRUST WASHER
2 - THRUST WASHER PIN
Fig. 15 JAW ON MAINSHAFT FIFTH GEAR
1 - MAINSHAFT FIFTH GEAR
2-JAW
3 - MAINSHAFT
Fig. 16 PULLER FLANGE
1-JAW
2 - PULLER FLANGE
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MANUAL TRANSMISSION - NV4500 (Continued)

(8) Remove countershaft rear bearing with Puller
Flange 6444-1 and Puller Rods 6444-4 (Fig. 37).
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.
(9) Position first Jaw 6449 on bearing cone and
seat puller flange in notch of puller.
(10) Install second Jaw 6449 on bearing and in
notch of puller flange. Slide 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.
(11) Install Puller 6444 on puller rods, then secure
puller to rods with retaining nuts.Tighten puller bolt
to remove bearing from shaft.
NOTE: If bearing is exceptionally tight, tap end of
puller bolt with copper mallet to help loosen bear-
ing.
(12) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 38).
(13) Remove countershaft front bearing, with
Puller Flange 6444-1 and Puller Bolts 6444-4 (Fig.
39).
(14) Position first Jaw 6451 on bearing and seat
puller flange in notch of puller jaw.
(15) Install second Jaw 6451 on bearing and in
notch of puller flange. Slide 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.(16) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts. Tighten
puller bolt to remove bearing from shaft.
NOTE: If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(17) Remove bearing puller tools.
Fig. 37 COUNTERSHAFT REAR BEARING
1 - COLLAR
2-JAWS
3 - PULLER
4 - WRENCH
Fig. 38 COUNTERSHAFT AND CASE
1 - COUNTERSHAFT
Fig. 39 Countershaft Front Bearing
1-JAWS
2 - COLLAR
3 - PULLER
4 - FLANGE
21 - 54 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)