DODGE RAM 1500 1998 2.G Workshop Manual

(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
21 - 48 MANUAL TRANSMISSION - NV4500DR
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)

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 28).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 29).
(4) Roll gear case onto left side.
(5) Remove mainshaft assembly (Fig. 30) by lifting
front end of mainshaft slightly. Then grasp mainshaft
rear splines and turn spline end of mainshaft coun-
terclockwise to rotate shaft and geartrain out of case.
Tilt mainshaft outward and removed from case.
NOTE: Handling mainshaft carefully because gears
are lose on the mainshaft.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
31).
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 32).
Fig. 28 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 29 FOURTH GEAR CLUTCH GEAR STOP RING
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
Fig. 30 MAINSHAFT AND GEARTRAIN
1 - MAINSHAFT AND CASE
Fig. 31 COUNTERSHAFT REAR BEARING PLATE
1 - REAR BEARING PLATE
2 - COUNTERSHAFT
Fig. 32 END PLAY SHIM AND REAR BEARING CUP
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
21 - 52 MANUAL TRANSMISSION - NV4500DR
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)

GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 40).
(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 41).(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 42). A small pin punch can be mod-
ified by putting a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 42).
(4) Remove shift lug rail.
Fig. 40 COUNTERSHAFT FRONT BEARING CAP
1 - HAMMER
2 - BEARING CAP
Fig. 41 COUNTERSHAFT FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 42 SHIFT LUG ROLL PIN
1 - PUNCH
2 - 30É BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
DRMANUAL TRANSMISSION - NV4500 21 - 55
MANUAL TRANSMISSION - NV4500 (Continued)

MAINSHAFT
NOTE: Gear and synchro components can be
installed backwards. Paint or scribe gear and syn-
chro components for installation reference. Then
stack geartrain parts in order of removal.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Place 3-4 gear in a press with support under
3rd gear and Remove 3-4 synchro hub, third gear
stop ring and third gear as an assembly (Fig. 43).
(3) Remove third gear bearing from mainshaft
(Fig. 44).
(4) Remove third gear bearing spacer (Fig. 45).
(5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 45).
Fig. 43 THIRD GEAR, STOP RING, AND 3-4 HUB
1 - THIRD GEAR
2 - THIRD GEAR STOP RING
3 - 3-4 SYNCHRO HUB
Fig. 44 THIRD GEAR BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 45 SNAP RING AND THIRD GEAR BEARING
SPACER
1 - SECOND GEAR THRUST WASHER
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
21 - 56 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(6) Remove second gear thrust washer (Fig. 46).
Note washer notch for locating pin.
(7) Remove thrust washer locating pin (Fig. 47)
with needle nose pliers.(8) Remove second gear (Fig. 48).
(9) Remove second gear bearing (Fig. 49).
Fig. 46 SECOND GEAR THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER
3 - SECOND GEAR BEARING
Fig. 47 THRUST WASHER LOCATING PIN
1 - THRUST WASHER LOCATING PIN
Fig. 48 SECOND GEAR
1 - SECOND GEAR
Fig. 49 SECOND GEAR BEARING
1 - SECOND GEAR NEEDLE BEARING
DRMANUAL TRANSMISSION - NV4500 21 - 57
MANUAL TRANSMISSION - NV4500 (Continued)