Washer DODGE RAM 1500 1998 2.G Workshop Manual

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
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(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
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(22) Remove bearing puller tools and rear main-
shaft bearing from output shaft.
(23) Remove reverse gear thrust washer (Fig. 59).
(24) Remove reverse gear and synchro components
as assembly (Fig. 60).CAUTION: Do not disassemble synchro compo-
nents unless they are damaged. If synchro sleeve
or struts require service, mark position of sleeve on
hub before removal. Correct sleeve position is
important as sleeve can be installed backwards
causing shift problems.
(25) Remove reverse gear bearing assembly from
mainshaft (Fig. 60).
(26) Remove reverse gear bearing spacer from
mainshaft (Fig. 61).
(27) Remove reverse clutch gear snap ring (Fig.
61). Heavy duty snap ring pliers will be required to
spread the ring far enough to remove it.
Fig. 58 MAINSHAFT REAR BEARING
1-JAWS
2 - COLLAR
3 - FLANGE
4 - MAINSHAFT
5 - PULLER
6 - TIGHTENING WRENCH
7 - HOLDING WRENCH
8 - RODS
Fig. 59 REVERSE GEAR THRUST WASHER
1 - REVERSE GEAR
2 - THRUST WASHER
Fig. 60 REVERSE GEAR, BEARING, AND STOP
RING
1 - FIRST GEAR
2 - REVERSE GEAR ASSEMBLY
3 - BEARING ASSEMBLY
4 - STOP RING
Fig. 61 REVERSE GEAR BEARING SPACER AND
FIRST GEAR SNAP RING
1 - CLUTCH GEAR SNAP RING
2 - REVERSE GEAR BEARING SPACER
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(28) Remove reverse clutch gear (Fig. 62).
(29) Remove first gear from bearing and mainshaft
(Fig. 63).
(30) Remove first gear bearing from mainshaft
(Fig. 64).
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Replace the gear if the teeth are chipped, cracked or
worn thin.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Replace the retainer if worn or
damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap
ring grooves and threads. Replace the shaft if any
surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or
damage.
Inspect shift forks for wear and distortion. Check
fit of the sleeve in the fork to be sure the two parts
fit and work smoothly. Replace the fork if the roll pin
holes are worn oversize or damaged. Do not attempt
to salvage a worn fork. Replace shift fork roll pins if
necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots,
pitting or other damage. Replace the bearings if nec-
essary.
Inspect the blocker rings and fiction cones. replace
either part if worn or damaged in any way. Replace if
the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the wash-
ers if worn or the locating pin notches are distorted.
Inspect the case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. InspcetFig. 62 Reverse Clutch Gear
1 - REVERSE CLUTCH GEAR
Fig. 63 FIRST GEAR
1 - FIRST GEAR
Fig. 64 FIRST GEAR BEARING
1 - MAINSHAFT
2 - FIRST GEAR BEARING
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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. 65).
(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. 66).
(5) Install countershaft in gear case (Fig. 66).
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. 67).
(7) Install idler gear front thrust washer on boss
in gear case (Fig. 67). Coat thrust washer with lib-
eral quantity of petroleum jelly to hold it in place.
Fig. 65 COUNTERSHAFT FRONT BEARING
1 - FRONT BEARING
2 - INSTALLER
3 - COUNTERSHAFT
Fig. 66 COUNTERSHAFT IN GEAR CASE
1 - GEAR CASE
2 - COUNTERSHAFT
Fig. 67 IDLER GEAR FRONT THRUST WASHER
1 - IDLER GEAR FRONT THRUST WASHER ON BOSS
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(8) Install reverse idler gear in case (Fig. 68).
(9) Install idler gear rear thrust washer between
idler gear and case boss (Fig. 68).
(10) Align idler gear bearings and thrust washers
with a drift.
(11) Install reverse idler shaft with notched end of
shaft facing countershaft (Fig. 69).(12) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 70).
(13) Install rear bearing cone on countershaft with
Installer C-4040 (Fig. 71).
Fig. 68 IDLER GEAR
1 - REAR THRUST WASHER
2 - REVERSE IDLER GEAR
3 - FRONT THRUST WASHER
Fig. 69 REVERSE IDLER SHAFT
1 - COUNTERSHAFT
2 - SHAFT NOTCH
3 - REVERSE IDLER SHAFT
Fig. 70 SUPPORTING COUNTERSHAFT
1 - COUNTERSHAFT
2 - WOOD BLOCK
Fig. 71 COUNTERSHAFT REAR BEARING
1 - INSTALLER
2 - REAR BEARING
3 - COUNTERSHAFT
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(14) Install thrust washer pin in shaft (Fig. 91).
(15) Install second gear thrust washer. Verify
washer is seated on gear and pin (Fig. 92).
(16) Install second gear thrust washer snap ring
(Fig. 93). Verify snap ring is seated in mainshaft
groove.
(17) Install third gear bearing spacer on shaft and
seat it against thrust washer snap ring (Fig. 93).
(18) Install third gear bearing on mainshaft (Fig.
94). Bearing should be flush with mainshaft hub.
NOTE: If bearing is not flush with hub, the bearing
spacer or snap ring was not installed.
(19) Install third gear over bearing and onto main-
shaft (Fig. 95).
Fig. 91 THRUST WASHER PIN
1 - THRUST WASHER PIN
2 - SECOND GEAR
Fig. 92 SECOND GEAR THRUST WASHER
1 - SECOND GEAR
2 - SECOND GEAR THRUST WASHER
3 - LOCATING PIN IN WASHER NOTCH
Fig. 93 SNAP RING AND THIRD
1 - SECOND GEAR THRUST WASHER
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
Fig. 94 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 95 THIRD GEAR
1 - THIRD GEAR
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(d) Compress first spring with flat blade screw-
driver and slide strut into position in hub slot.
Then work spring into seat in strut with small
hooked tool or screwdriver.
(e) Install second and third struts in same man-
ner as described in step (d).
(f) Work sleeve upward on hub until struts are
centered and seated in sleeve. Sleeve should be in
neutral position after seating struts.
(34) Install reverse gear and synchro assembly on
mainshaft (Fig. 103). Rotate assembly until stop ring
lugs engage in hub slots and gear drops into seated
position.
(35) Install reverse gear thrust washer (Fig. 104).
(36) Install rear bearing on mainshaft with
Installer 6446. Seat bearing on output shaft and
against thrust washer (Fig. 105).
(37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 106).
(38) Install fourth gear clutch gear in stop ring
(Fig. 107).
Fig. 103 REVERSE GEAR
1 - REVERSE GEAR AND SYNCHRO ASSEMBLY
Fig. 104 REVERSE GEAR THRUST WASHER
1 - THRUST WASHER
2 - REVERSE GEAR
Fig. 105 MAINSHAFT REAR BEARING
1 - INSTALLER
2 - MAINSHAFT REAR BEARING
Fig. 106 FOURTH GEAR STOP RING
1 - 3-4 SYNCHRO SLEEVE
2 - FOURTH SPEED STOP RING
Fig. 107 FOURTH GEAR CLUTCH GEAR
1 - FOURTH SPEED CLUTCH GEAR
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(12) Install mainshaft fifth gear with Installer
6446 (Fig. 116). Gear is seated when it contacts rear
bearing.
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) Install thrust washer pin in countershaft (Fig.
117).
(2) Install thrust washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 118).
NOTE: The flat side of washer faces the rear and
cone side faces the front.
(3) Lubricate and install fifth gear bearing on
countershaft (Fig. 119).
Fig. 115 REAR BEARING PLATE
1 - BEARING PLATE OIL HOLE (AT TOP)
2 - MAINSHAFT REAR BEARING PLATE
Fig. 116 MAINSHAFT FIFTH GEAR
1 - MAINSHAFT FIFTH GEAR
2 - INSTALLER
Fig. 117 FIFTH GEAR THRUST WASHER PIN
1 - THRUST WASHER PIN
2 - COUNTERSHAFT
Fig. 118 FIFTH GEAR THRUST WASHER
1 - PIN
2 - THRUST WASHER
Fig. 119 COUNTERSHAFT FIFTH GEAR BEARING
1 - COUNTERSHAFT
2 - FIFTH GEAR NEEDLE BEARING
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(8) Assemble and install fifth synchro clutch gear
and stop ring in fifth gear hub (Fig. 124). Verify
parts are seated in fifth gear hub.
(9) Install clutch gear snap ring (Fig. 125).
(10) Align roll pin holes in shift fork with notches
in shift lug rail. Then install roll pins from top side
of fork (Fig. 122).
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. 126).
(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. 127).
(9) Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
Fig. 124 FIFTH SYNCHRO CLUTCH GEAR AND
STOP RING
1 - STOP RING
2 - CLUTCH GEAR
Fig. 125 FIFTH SYNCHRO CLUTCH SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
Fig. 126 FIFTH GEAR NUT
1 - FIFTH GEAR
2 - FIFTH GEAR NUT
Fig. 127 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SOCKET
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