Transmission install DODGE RAM 1500 1998 2.G Workshop Manual

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crossmember Nuts 102 75 -
Transmission Mount Bolts 4WD 68 50 -
Transmission Mount Bolts 2WD 68 50 -
Structural Dust Cover Bolts 54 40 -
Drain/Fill Plug 9-27 14-20 -
Front To Rear Housing Bolts 30-35 22-26 -
Front Bearing Retainer Bolts 7-10 5-7 62-88
Idler Shaft Bolts 19-25 14-18 -
Rear Bearing Retainer Bolts 30-35 22-26 -
Shift Tower Bolts 7-10 5-7 62-88
Slave Cylinder Nuts 23 17 -
Transfer Case Nuts 47 35 -
SPECIAL TOOLS
REMOVER C-3985-B
INSTALLER C-3972-A
REMOVER 6957
INSTALLER 6951
HANDLE C-4171
21 - 40 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

REMOVER/INSTALLER 6858
FIXTURE 6747
ADAPTER 6747-1A
ADAPTER 6747-2A
CUP 8115
BEARING SPLITTER 1130
TUBE 6310-1
INSTALLER 8118
REMOVER/INSTALLER 8119
ALIGNMENT STUD 8120
DRMANUAL TRANSMISSION - NV3500 21 - 41
MANUAL TRANSMISSION - NV3500 (Continued)

INSTALLER C-3860-A
INSTALLER 8123
INSTALLER 6448
REMOVER 8117A
21 - 42 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

MANUAL TRANSMISSION - NV4500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV4500
DESCRIPTION.........................43
OPERATION...........................43
DIAGNOSIS AND TESTING................44
REMOVAL.............................44
DISASSEMBLY.........................46
CLEANING............................62
INSPECTION..........................62
ASSEMBLY............................63
INSTALLATION.........................80
SPECIFICATIONS.......................81
SPECIAL TOOLS.......................81ADAPTER HOUSING SEAL
REMOVAL.............................85
INSTALLATION.........................85
EXTENSION HOUSING SEAL
REMOVAL.............................85
INSTALLATION.........................85
SHIFT MECHANISM
REMOVAL.............................86
INSTALLATION.........................87
SHIFT COVER
REMOVAL.............................87
INSTALLATION.........................87
MANUAL TRANSMISSION -
NV4500
DESCRIPTION
The NV4500 is a five speed constant mesh manual
transmission. All gear ranges including reverse are
synchronized. Fifth gear is an overdrive range. The
transmission has a cast iron gear case and aluminum
shift cover.
Two versions are used, a standard duty for 5.7L
applications and a heavy duty for V10 and Cummins
diesel applications. Main difference is a larger diam-
eter input shaft, for the heavy duty model.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Roller
bearings in the drive gear support the forward end of
the mainshaft. The mainshaft gears are all supported
on caged type roller bearings. Drive gear thrust reac-
tion is controlled by a needle type thrust bearing.
The bearing is located at the forward end of the
mainshaft.
The transmission is a top loader style. The shift
lever is located in a shifter tower which is bolted to
the shift cover and operates the shift forks and rails
directly. The shift forks and rails are all located
within the aluminum cover which is bolted to the top
of the gear case.
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 1).
The tag provides the transmission model number,
build date and part number. Be sure to reinstall the
I.D. tag if removed during service. The information
on the tag is essential to correct parts ordering.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point all the transmission gears
are spinning.
Fig. 1 IDENTIFICATION TAG LOCATION
1 - PTO COVER
2 - I.D. TAG
DRMANUAL TRANSMISSION - NV4500 21 - 43

(3) Remove rubber spline seal from end of main-
shaft (Fig. 9). 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. 10).
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. 11).
Drive roll pins out from the bottom of fork.
(2) Remove fifth gear clutch hub and gear snap
ring from countershaft (Fig. 12).
(3) Remove countershaft fifth gear clutch gear and
stop ring.
(4) Tap off fifth gear shift fork and gear assembly
off rail with plastic mallet.
(5) Remove fifth gear shift fork from sleeve.
(6) Remove sleeve, struts and strut springs from
countershaft fifth gear hub, if necessary.
Fig. 10 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SPLINE SOCKET
Fig. 9 MAINSHAFT SPLINE SEAL
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 11 FIFTH GEAR SHIFT FORK ROLL PINS
1 - ROLL PINS
2 - FIFTH GEAR SHIFT FORK
Fig. 12 FIFTH GEAR CLUTCH GEAR SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 47
MANUAL TRANSMISSION - NV4500 (Continued)

(12) Position second puller jaw on gear and in
notch of puller flange (Fig. 17). Slide Collar 6444-8
over puller jaws to hold them in place.
(13) Install Puller and Bolt 6444 on puller rods
and secure puller to rods with retaining nuts (Fig.
18). Tighten puller bolt to remove gear from shaft
splines.(14) Remove mainshaft rear bearing plate bolts
and remove fifth gear plate end play shims and bear-
ing cup (Fig. 19).
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 20).
CAUTION: Do not reuse retainer bolts.
(2) Lightly tap retainer back and forth with plastic
mallet to work it out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
Fig. 17 PULLER COLLAR
1-JAWS
2 - COLLAR
Fig. 18 PULLER ASSEMBLY
1 - COLLAR
2-JAWS
3 - BOLT
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE
Fig. 19 FIFTH GEAR BEARING PLATE, SHIMS AND
BEARING CUP
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 20 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
DRMANUAL TRANSMISSION - NV4500 21 - 49
MANUAL TRANSMISSION - NV4500 (Continued)

(3) Remove front retainer seal by (Fig. 21) collaps-
ing one side of seal then prying it out.
(4) Remove front retainer bearing cup with Puller
6444. Assemble Puller Flange 6444-1 and Puller Rods
6444-4 (Fig. 22). Insert Jaws 6453-1 in puller flange.
Narrow lip of puller jaws will go under bearing cup.
(5) Install Disc C-4487-1 into bearing retainer for
Insert 6453-2 to rest upon.(6) Install assembled tools in front retainer (Fig.
23) with puller jaws seated under bearing cup. Place
Insert 6453-2 in center of puller jaws, to hold puller
jaws in place.
(7) Install Puller 6444 on puller rods (Fig. 24) and
install retaining nuts on puller rods. Tighten puller
bolt to draw bearing cup out of retainer.
Fig. 21 BEARING RETAINER SEAL
1 - SEAL
2 - FRONT BEARING RETAINER
Fig. 22 PULLER RODS, FLANGE AND JAWS
1 - RODS
2 - FLANGE
3-JAWS
Fig. 23 INSERT AND RETAINER
1 - INSERT
2 - FRONT RETAINER
3-JAWS
Fig. 24 BEARING CUP PULLER ASSEMBLY
1 - WRENCH
2 - INSERT
3 - FRONT RETAINER
4 - PULLER
5 - WRENCH
21 - 50 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

DRIVE GEAR
(1) Remove drive gear (Fig. 25).
(2) Remove pilot bearing from drive gear (Fig. 26).(3) Remove tapered bearing from drive gear with
Puller Flange 6444-1 and Puller Rods 6444-6 (Fig.
27).
(4) Position first Jaw 6447 on bearing. Slide
assembled puller flange and rod tools onto input
shaft. Then seat flange in notch of puller jaw.
(5) Position second Jaw 6447 on gear and in notch
of puller flange. Slide Collar 6444-8 over puller jaws
to hold them in place.
(6) Install Puller 6444 on puller rods then install
retaining nuts. Tighten puller bolt to remove bearing
cone from drive gear.
Fig. 25 DRIVE GEAR
1 - MAINSHAFT
2 - DRIVE GEAR
Fig. 26 PILOT BEARING
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 27 FRONT BEARING PULLER
1 - PULLER
2 - RODS
3-JAWS
4 - COLLAR
5 - FLANGE
6 - DRIVE GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 51
MANUAL TRANSMISSION - NV4500 (Continued)

(3) Remove reverse idler shaft (Fig. 33).
(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 34).(5) Remove idler gear (Fig. 35).
(6) Keep reverse idler gear bearings and spacer
together (Fig. 36). Insert idler shaft through gear and
bearings to keep them in place.
(7) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them
together for cleaning and inspection.
Fig. 33 REVERSE IDLER SHAFT
1 - REVERSE IDLER SHAFT
Fig. 34 IDLER GEAR AND COUNTERSHAFT
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT
Fig. 35 REVERSE IDLER GEAR
1 - REVERSE IDLER GEAR
2 - DRIVE GEAR BORE
Fig. 36 IDLER GEAR COMPONENTS
1 - BEARINGS
2 - REVERSE IDLER GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 53
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)