four wheel drive DODGE RAM 1500 1998 2.G User Guide

DRIVER AIRBAG
DESCRIPTION
The color-keyed, injection molded, thermoplastic
driver airbag protective trim cover is the most visible
part of the driver airbag (Fig. 21). The driver airbag
is located in the center of the steering wheel, where
it is secured with two screws to the armature of the
four-spoke steering wheel. All models have a chrome
Dodge Ram emblem in the center of the trim cover.
Concealed beneath the driver airbag trim cover are
the horn switch, the folded airbag cushion, the airbag
cushion retainer, the airbag housing, the airbag infla-
tor, and the retainers that secure the inflator to the
airbag housing.
The airbag cushion, housing, and inflator are
secured within an integral receptacle molded into the
back of the trim cover. The four vertical walls of this
receptacle have a total of twelve small windows with
blocking tabs that are engaged by twelve hook forma-
tions around the perimeter of the airbag housing.
Each hook is inserted through one of the windows
and the blocking tab in each window keeps the hook
properly engaged with the trim cover, locking the
trim cover securely into place on the airbag housing.
The resistive membrane-type horn switch is
secured with heat stakes to the inside surface of the
driver airbag trim cover, between the trim cover and
the folded airbag cushion. The horn switch ground
pigtail wire has an eyelet terminal connector that is
captured beneath a flanged nut on the upper right
inflator mounting stud on the back of the housing
(Fig. 22). The horn switch feed pigtail wire has a
black, molded plastic insulator that is secured by an
integral retainer in a locator hole near the upper
right corner of the airbag housing and is connected tothe vehicle electrical system through a dedicated
take out and connector of the steering wheel wire
harness. Both horn switch wires are routed through
an integral notch in the center of the upper edge of
the airbag housing stamping.
The airbag used in this model is a multistage, Next
Generation-type that complies with revised federal
airbag standards to deploy with less force than those
used in some prior models. A 71 centimeter (28 inch)
diameter, radial deploying fabric cushion with inter-
nal tethers is used. The airbag inflator is a dual-ini-
tiator, non-azide, pyrotechnic-type unit with four
mounting studs and is secured to the stamped metal
airbag housing by four flanged hex nuts. Two keyed
and color-coded connector receptacles on the driver
airbag inflator connect the two inflator initiators to
the vehicle electrical system through two yellow-jack-
eted, two-wire pigtail harnesses of the clockspring.
The driver airbag unit cannot be repaired, and
must be replaced if deployed or in any way damaged.
The driver airbag trim cover and horn switch unit
may be disassembled from the driver airbag unit,
and is available for separate service replacement.
OPERATION
The multistage driver airbag is deployed by electri-
cal signals generated by the Airbag Control Module
(ACM) through the driver airbag squib 1 and squib 2
circuits to the two initiators in the airbag inflator. By
using two initiators, the airbag can be deployed at
multiple levels of force. The force level is controlled
Fig. 21 Driver Airbag Trim Cover
1 - STEERING WHEEL
2 - TRIM COVER
Fig. 22 Driver Airbag Housing
1 - HORN SWITCH FEED WIRE
2 - HORN SWITCH GROUND WIRE
3 - INFLATOR
4 - TRIM COVER
5 - HOUSING
DRRESTRAINTS 8O - 23

(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head and cam on camshaft at
base circle. Depress part of rocker arm over adjuster.
Normal adjusters should feel very firm. Spongy
adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and replace.
c. Before installation, make sure adjusters are at
least partially full of oil. This can be verified by little
or no plunger travel when lash adjuster is depressed.
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the right side
exhaust manifold.
(4) Drain the engine coolant(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(5) Lower the vehicle.
(6) Remove the intake manifold(Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(7) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(8) Remove the fan shroud(Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove oil fill housing from cylinder head.
(10) Remove accessory drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark.
(12) Verify the V6 mark on the camshaft sprocket
is at the 12 o'clock position. Rotate the crankshaft
one turn if necessary.
(13) Remove the crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(14) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8429 Timing Chain Hold-
ing Fixture.NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary timing chain, one link on
each side of the V6 mark on the camshaft drive gear.
(17) Remove the right side secondary chain ten-
sioner(Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT/CHAIN AND SPROCKETS - REMOVAL).
(18) Remove the cylinder head access plug.
(19) Remove the right side secondary chain
guide(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL).
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed,
torque nut to 5 N´m (44 in. lbs.).
(20) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with twelve bolts.
(21) Remove the cylinder head retaining bolts.
(22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
DRENGINE - 3.7L 9 - 33
CYLINDER HEAD - RIGHT (Continued)

CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed,
torque nut to 5 NM ( 60 in. lbs.).
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V6 mark on the gear then using
Special Tool 8428 Camshaft Wrench, position the
gear onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torquing of bolt result-
ing in bolt failure.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the right side secondary chain guide(Re-
fer to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION).
(10) Install the cylinder head access plug.
(11) Re-set and install the right side secondary
chain tensioner(Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION).
(12) Remove Special Tool 8429.
(13) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(14) Install the crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION). Tighten damper bolt 175 N´m (130
Ft. Lbs.).
(15) Install accessory drive belt(Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(16) Install the fan shroud(Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(17) Install the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install the intake manifold(Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(19) Install oil fill housing onto cylinder head.
(20) Refill the cooling system(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(21) Raise the vehicle.
(22) Install the exhaust pipe onto the right
exhaust manifold.
(23) Lower the vehicle.
(24) Reconnect battery negative cable.
(25) Start the engine and check for leaks.CAMSHAFT(S)
DESCRIPTION
The camshafts consist of powdered metal steel
lobes which are sinter-bonded to a steel tube. Four
bearing journals are machined into the camshaft.
Camshaft end play is controlled by two thrust walls
that border the nose piece journal. Engine oil enters
the hollow camshafts at the third journal and lubri-
cates every intake lobe rocker through a drilled pas-
sage in the intake lobe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use special tool 8379
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Set engine to TDC cylinder No. 1, camshaft
sprocket V6 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V6 mark on the camshaft
sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen butDO NOTremove the camshaft
sprocket retaining bolt. Leave bolt snug against
sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
DRENGINE - 3.7L 9 - 35
CYLINDER HEAD - RIGHT (Continued)

(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8515 (Fig. 15).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary timing chain, one link on
each side of the V8 mark on the camshaft drive gear
(Fig. 14).
(17) Remove the right side secondary chain ten-
sioner (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT/CHAIN AND SPROCKETS - REMOVAL).
(18) Remove the cylinder head access plug (Fig.
16).
(19) Remove the right side secondary chain guide
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL).
(20) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(21) Remove the cylinder head retaining bolts.
(22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components. (Refer to 9 -
ENGINE - STANDARD PROCEDURE)
INSPECTION
(1) Inspect the cylinder head for out-of-flatness,
using a straightedge and a feeler gauge. If tolerances
exceed 0.0508 mm (0.002 in.) replace the cylinder
head.
(2) Inspect the valve seats for damage. Service the
valve seats as necessary.
(3) Inspect the valve guides for wear, cracks or
looseness. If either condition exist, replace the cylin-
der head.
Fig. 15 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
6 - SPECIAL TOOL 8515
Fig. 16 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
DRENGINE - 4.7L 9 - 111
CYLINDER HEAD (Continued)

CORE PLUGS
REMOVAL
(1) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(2) Using a blunt tool such as a drift or a screw
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 55)
(3) Using a suitable pair of pliers, grasp the core
plug and remove.
INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all
of the old sealer.
(1) Coat the edges of the engine core plug and the
core plug bore with Mopar Gasket Maker, or equiva-
lent.
NOTE: It is not necessary to wait for the sealant to
cure on the core plugs. The cooling system can be
filled and the vehicle returned to service immedi-
ately.
(2) Using proper plug driver, drive core plug into
the core plug bore. The sharp edge of the core plug
should be at least 0.50 mm (0.020 in.) inside the lead
in chamfer.
(3) Refill the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a crosshaped four throw design
with eight counterweights for balancing purposes.
The crankshaft is supported by five select fit main
bearings with the number three serving as the thrust
washer location. The main journals of the crankshaft
are cross drilled to improve rod bearing lubrication.
The number eight counterweight has provisions for
crankshaft position sensor target wheel mounting.
The select fit main bearing markings are located on
the rear side of the target wheel. The crankshaft oil
seals are one piece design. The front oil seal is
retained in the timing chain cover, and the rear seal
is pressed in to a bore formed by the cylinder block
and the bedplate assembly.
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engine. (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove the engine oil pump.(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(4) Remove the oil pump pickup tube and oil pan
gasket /windage tray.
(5) Remove the bedplate mounting bolts. Note the
location of the three stud bolts for installation.
(6) Remove the connecting rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
Fig. 55 Engine Core Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
DRENGINE - 4.7L 9 - 131

(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N´m (101 ft. lbs.) torque.
(8) Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
(11) Connect battery negative cables.
(12) Check engine oil level and adjust, if necessary.
(13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan drain plug and drain the
engine oil. Re-install plug and torque to 50 N´m (44
ft. lbs.) torque.
(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5)
Remove flywheel or torque converter drive plate.
(6) Disconnect starter cables from starter motor.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(8) Remove four (4) oil pan rear bolts. Slide a
feeler gauge between the seal retainer and oil pan
gasket to break the seal.(9) Remove the six (6) retainer-to-block bolts (Fig.
73).
(10) Remove the rear seal retainer and gasket
(Fig. 73).
(11) Support the seal retainer and drive out the
crankshaft seal with a hammer and suitable punch.
INSTALLATION
(1) If using the old seal retainer, the crankshaft
seal must be replaced.
(2) Inspect oil pan gasket for nickes or cuts. If gas-
ket is damaged, the oil pan must be removed and
gasket must be replaced. Wipe oil pan gasket dry and
apply light coating of RTV.
(3) Using the retainer alignment/seal installation
tool provided in the seal service kit, install the align-
ment tool into the retainer and install to the cylinder
block (Fig. 74), using a new gasket. Tighten the six
(6) mounting bolts by hand.
(4) The seal alignment tool is used to align rear
cover properly. Starting with the center two bolts,
tighten the retainer in a circular pattern to 10 N´m
(89 in. lbs.). Remove the alignment tool.
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
Fig. 72 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 73 Crankshaft Rear Seal Retainer and Gasket
1 - RETAINER
2 - GASKET
3 - BOLT
DRENGINE 5.9L DIESEL 9 - 277
CRANKSHAFT OIL SEAL - REAR (Continued)

(5) Make sure the provided seal pilot is installed
into the new crankshaft seal. Use the alignment/in-
stallation tool and press the seal onto the crankshaft
(Fig. 75). Alternately drive the seal at the 12, 3, 6
and 9 o'clock positions.
(6) Remove the alignment tool and trim the
retainer gasket even with the oil pan mounting sur-
face (Fig. 76).
(7) Remove the seal pilot.
(8) Apply a small amount of MopartSilicone Rub-
ber Adhesive Sealant to the oil pan rail T-joints.
(9) Install the four (4) oil pan rear mounting bolts
and torque to 28 N´m (21 ft. lbs.).
(10) Install new rectangular ring seal for cam bore.
(11) Install the flywheel housing and bolts. Torque
bolts to 77 N´m (57 ft. lbs.).
(12) Install the flywheel or converter drive plate.
Tighten bolts to 137 N´m (101 ft. lbs.).
(13) Install the starter motor Refer to (Refer to 8 -
ELECTRICAL/STARTING/STARTER MOTOR -
INSTALLATION).
(14) Install the transmission and transfer case (if
equipped).
(15) Lower vehicle.(16) Fill the crankcase with new engine oil.
(17) Connect the battery negative cables.
(18) Start engine and check for oil leaks.
Fig. 74 Aligning Seal Retainer with Alignment/
Installation Tool
1 - ALIGNMENT / INSTALLATION TOOL
2 - SEAL RETAINER
Fig. 75 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 76 Trimming Excess Gasket Material
1 - GASKET
9 - 278 ENGINE 5.9L DIESELDR
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

(2) Cycle the key from ACC to RUN and ensure
that the blocker does not stick or bind.
(3) Turn the key to the OFF position and ensure
that the shifter will not pull from the PARK position.
(4) Connect the over drive switch harness (if
equipped).
NOTE: Route and tie off harness to original loca-
tion.
(5) Connect the shift cable to the lever.
(6) Ensure the gear shift lever and transmission
are in the PARK position and snap the cable adjust
clip in place.
(7) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(8) Install the SKIM and halo.
(9) Install the upper and lower column shroud.
(10) Install the column back into place and
tighten.
(11) Install the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
UPPER STEERING COUPLING
REMOVAL
(1) Disconnect the negative battery cable.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.(2) Lock the steering wheel with the tire in the
straight position.
(3) Remove and discard the lower pinch bolt.
(4) Lower the steering coupler shaft from the col-
umn.
(5) Remove the upper steering coupling shaft seal
by pushing in the four tags securing it to the panel
(Fig. 16).
(6) Remove and discard the lower coupler pinch
bolt from the lower steering coupling shaft (Fig. 17).
(7) Remove the upper steering coupling shaft from
the vehicle (Fig. 17).
INSTALLATION
(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).
Fig. 15 GEAR SHIFT LEVER SPRING
1 - BLOCKER TO INHIBIT LINK SLOT
2 - GEAR SHIFT LEVER
Fig. 16 RELEASE TANGS
1 - RELEASE TANGS (4)
2 - UPPER STEERING COUPLER SHAFT
Fig. 17 UPPER STEERING COUPLER SHAFT
1 - LOWER STEERING COUPLER
2 - RELEASE TANGS (4)
3 - UPPER STEERING COUPLER SHAFT
DRCOLUMN 19 - 13
GEAR SHIFT LEVER (Continued)

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500..........1
MANUAL TRANSMISSION - NV4500..........43
MANUAL TRANSMISSION - NV5600..........88
AUTOMATIC TRANSMISSION - 48RE........130
AUTOMATIC TRANSMISSION - 45RFE/545RFE.311
TRANSFER CASE - NV241 GENII...........415TRANSFER CASE - NV271................447
TRANSFER CASE - NV243................482
TRANSFER CASE - NV244 GENII...........512
TRANSFER CASE - NV273................542
MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING................3
REMOVAL.............................3
DISASSEMBLY..........................4CLEANING............................15
INSPECTION..........................16
ASSEMBLY............................17
INSTALLATION.........................39
SPECIFICATIONS.......................40
SPECIAL TOOLS.......................40
MANUAL TRANSMISSION -
NV3500
DESCRIPTION
The transmission is a medium-duty 5-speed, con-
stant mesh fully synchronized manual transmission
with fifth gear overdrive range. The transmission is
available in two and four-wheel drive configurations.
The transmission gear case consists of two aluminum
housings (Fig. 1). The clutch housing is an integral
part of the transmission front housing.
A combination of roller and ball bearings are used
to support the transmission shafts in the two hous-
ings. The transmission gears all rotate on caged type
needle bearings. A roller bearing is used between the
input and output shaft.
The transmission has a single shaft shift mecha-
nism with three shift forks all mounted on the shaft.
The shaft is supported in the front and rear housings
by bushings and one linear ball bearing. Internal
shift components consist of the forks, shaft, shift
lever socket and detent components
OPERATION
The manual transmission receives power through the
clutch assembly from the engine. The clutch disc issplined 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 transmission coun-
tershaft through the mesh of fourth speed gear on the
input shaft and the fourth countershaft gear. At this
point, all the transmission gears are spinning.
The driver selects a particular gear by moving the
shift lever to the desired gear position. This movement
moves the internal transmission shift components to
begin the shift sequence. As the shift lever moves the
selected shift rail, the shift fork attached to that rail
begins to move. The fork is positioned in a groove in the
outer circumference of the synchronizer sleeve. As the
shift fork moves the synchronizer sleeve, the synchro-
nizer begins to speed-up or slow down the selected gear
(depending on whether we are up-shifting or down-shift-
ing). The synchronizer does this by having the synchro-
nizer hub splined to the mainshaft and moving the
blocker ring into contact with the gear's friction cone. As
the blocker ring and friction cone come together, the
gear speed is brought up or down to the speed of the
synchronizer. As the two speeds match, the splines on
the inside of the synchronizer sleeve become aligned
with the teeth on the blocker ring and the friction cone
and eventually will slide over the teeth, locking the gear
to the mainshaft, or countershaft, through the synchro-
nizer.
DRTRANSMISSION AND TRANSFER CASE 21 - 1

(5) Remove shift tower and isolator plate from
transmission shift cover.
(6) Raise and support vehicle.
(7) Remove skid plate, if equipped.
(8) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(9) Remove exhaust system Y-pipe.
(10) Disconnect speed sensor and backup light
switch connectors.
(11) Support engine with safety stand and a wood
block.
(12) If transmission is to be disassembled, remove
drain bolt at bottom of PTO cover and drain lubri-
cant (Fig. 3).
TWO WHEEL DRIVE
(1) Remove bolts attaching transmission to rear
crossmember mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmenber.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
NOTE: The hydraulic linkage has a quick connect at
the slave cylinder. This fitting should not be discon-
nected.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 4).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(9) Remove rear crossmember bolts and pry out
crossmenber.
(10) Remove clutch slave cylinder splash shield, if
equipped.
(11) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
NOTE: The hydraulic linkage has a quick connect at
the slave cylinder. This fitting should not be discon-
nected.
(12) Remove transmission to clutch housing bolts.
(13) Slide transmission and jack rearward until
input shaft clears clutch housing.
(14) Lower transmission jack and remove trans-
mission from under vehicle.
Fig. 3 FILL AND DRAIN PLUGS
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
Fig. 4 TRANSFER CASE SHIFTER-TYPICAL
1 - TRANSMISSION
2 - TRANSFER CASE SHIFT MECHANISM
DRMANUAL TRANSMISSION - NV4500 21 - 45
MANUAL TRANSMISSION - NV4500 (Continued)