service DODGE RAM 1500 1998 2.G Workshop Manual

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

(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
DRMANUAL TRANSMISSION - NV4500 21 - 61
MANUAL TRANSMISSION - NV4500 (Continued)

(2) Install first gear clutch cone on mainshaft 1-2
synchro hub with recessed side of cone facing front
(Fig. 79). Verify cone is seated against snap ring on
hub.
(3) Install snap ring on mainshaft 1-2 synchro hub
to secure clutch cone (Fig. 80). Verify snap ring is
seated in hub groove and against clutch cone.
(4) Support mainshaft in upright position to install
remaining gears, snap rings and synchro compo-
nents. Shaft can be supported in gear case or hole
can be cut in workbench to support shaft.
(5) If 1-2 synchro hub and sleeve were disassem-
bled for service, reassemble hub, sleeve, struts and
springs as follows:(a) Align and install sleeve on hub. Rotate sleeve
until it slides onto hub. Sleeve only fits one way
and will easily slide onto hub when long slot in
sleeve, aligns with long shoulder on hub (Fig. 81).
(b)
Place wood blocks under hub that will raise hub
about 3.5 cm (1.375 in.) above surface of workbench.
Then allow sleeve to drop down on hub (Fig. 82).
(c)Install springs and struts in hub (Fig. 82). Use
lots of petroleum jelly to hold them in place. Then
compress struts with your fingers and move sleeve
upward until struts are started in sleeve. Verify that
struts are engaged in sleeve before proceeding.
(d) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated
and springs are not displaced during assembly.
Fig. 79 FIRST GEAR CLUTCH CONE
1 - MAINSHAFT 1-2 SYNCHRO HUB
2 - FIRST GEAR CLUTCH CONE
Fig. 80 FIRST GEAR CLUTCH CONE SNAP RING
1 - FIRST GEAR CLUTCH CONE
2 - MAINSHAFT 1-2 SYNCHRO HUB
3 - CLUTCH CONE SNAP RING
Fig. 81 1-2 SYNCHRO SLEEVE ON HUB
1 - ALIGN WIDE SLOT IN SLEEVE WITH WIDE SPLINE OF HUB
2 - 1-2 SLEEVE AND HUB
Fig. 82 1-2 SYNCHRO STRUTS AND SPRINGS
1 - WOOD BLOCKS
2 - HUB
3 - SLEEVE
4 - STRUTS AND SPRINGS (4 EACH)
DRMANUAL TRANSMISSION - NV4500 21 - 67
MANUAL TRANSMISSION - NV4500 (Continued)

(20) Install synchro stop ring on third gear (Fig.
96). Verify stop ring is seated on cone taper.
(21) If 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align and install synchro sleeve on hub (Fig.
97).Front side of hub has a narrow groove
machined in it.
(b) Insert all three synchro struts in slots
machined in sleeve and hub (Fig. 97).
(c) Install and seat synchro springs (Fig. 97).
Use screwdriver to compress springs and seat them
in struts and hub as shown.(22) Start 3-4 synchro assembly on mainshaft with
the hub groove and sleeve groove both facing for-
ward. Tap assembly onto shaft splines until hub is
about 3 mm (0.125 in.) away from third gear stop
ring. Then align stop ring with synchro sleeve and
hub and seat synchro assembly with Installer C-4040
(Fig. 98).
(23) Verify 3-4 synchro hub is seated on shaft with
approximately 3 mm (0.125 in.) of shaft spline visi-
ble.
NOTE: If hub is not seated, stop ring lugs are mis-
aligned. Rotate ring until lugs are engaged in 3-4
hub slots.
(24) Verify that second and third gear rotate freely
at this point. If not, determine the cause and correct.
(25) Invert mainshaft in case or bench.
(26) Install first gear bearing on mainshaft.
(27) Install first gear on shaft with clutch hub side
of gear facing the front of shaft (Fig. 99). Verify tabs
on clutch ring are aligned and seated in first gear
hub.
NOTE: 1-2 synchro hub will not seat properly if
clutch ring tabs are misaligned.
Fig. 96 THIRD GEAR STOP RING
1 - SYNCHRO STOP RING
2 - THIRD GEAR
Fig. 97 SYNCHRO ASSEMBLY (3-4)
1 - STRUT (3)
2 - SPRING (3)
3 - 3-4 SLEEVE
4 - 3-4 HUB
Fig. 98 SEATING 3-4 SYNCHRO ASSEMBLY ON
MAINSHAFT
1 - 3-4 SYNCHRO HUB
2 - HUB GROOVE
3 - INSTALLER C-4040
DRMANUAL TRANSMISSION - NV4500 21 - 71
MANUAL TRANSMISSION - NV4500 (Continued)

(28) Install reverse clutch gear on first gear (Fig.
99). Verify clutch gear is seated on shaft splines.
(29) Install reverse clutch gear snap ring with
heavy duty snap ring pliers (Fig. 99). Verify snap
ring is seated in groove.
NOTE: Reverse gear will not fit properly if snap ring
is not seated.
(30) Install stop ring on clutch cone (Fig. 100). Ver-
ify stop ring is seated on cone taper.
(31) Install reverse gear bearing spacer on main-
shaft and seat against reverse clutch gear snap ring
(Fig. 101).
(32) Install reverse gear bearing on mainshaft
(Fig. 101).
(33) If reverse gear sleeve and struts were disas-
sembled for service, reassemble sleeve, struts and
springs as follows:CAUTION: The reverse sleeve will fit either way on
the hub. Verify tapered side of the sleeve faces
rearward.
(a) Position sleeve on hub so tapered side of
sleeve faces rearward. (Fig. 102).
(b) Rotate sleeve to align teeth on sleeve and
hub. Sleeve will slide easily into place on hub when
properly aligned.
(c) Install springs in gear hub (Fig. 102). Use
petroleum jelly to hold springs in place if desired.
Fig. 102 REVERSE GEAR SYNCHRO ASSEMBLY
1 - REVERSE GEAR
2 - SLEEVE
3 - SPRING (3)
4 - STRUT (3)
5 - HUB
Fig. 99 FIRST GEAR AND CLUTCH GEAR
1 - FIRST GEAR
2 - REVERSE CLUTCH GEAR SNAP RING
3 - REVERSE CLUTCH GEAR
Fig. 100 CLUTCH GEAR STOP RING
1 - REVERSE GEAR STOP RING
2 - CLUTCH GEAR
3 - FIRST GEAR
Fig. 101 REVERSE GEAR BEARING AND SPACER
1 - REVERSE GEAR BEARING
2 - BEARING SPACER
3 - FIRST GEAR
21 - 72 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(3) Have helper start and run engine at 1600 rpm
for test.
(4)
Move transmission shift lever four detents rear-
ward from full forward position. This is Reverse range.
(5) Move transmission throttle lever fully forward
then fully rearward and note reading at Gauge
C-3293-SP.
(6) Pressure should be 145 - 175 psi (1000-1207
kPa) with throttle lever forward and increase to 230 -
280 psi (1586-1931 kPa) as lever is gradually moved
rearward.
Test Five - Governor Pressure
This test checks governor operation by measuring
governor pressure response to changes in vehicle
speed. It is usually not necessary to check governor
operation unless shift speeds are incorrect or if the
transmission will not downshift. The test should be
performed on the road or on a hoist that will allow
the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(2) Move transmission shift lever two detents rear-
ward from full forward position. This is D range.
(3) Have helper start and run engine at curb idle
speed. Then firmly apply service brakes so wheels
will not rotate.
(4) Note governor pressure:
²
Governor pressure should be no more than 20.6
kPa (3 psi) at curb idle speed and wheels not rotating.
²If pressure exceeds 20.6 kPa (3 psi), a fault
exists in governor pressure control system.
(5) Release brakes, slowly increase engine speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure should increase in proportion to vehicle speed.
Or approximately 6.89 kPa (1 psi) for every 1 mph.
(6) Governor pressure rise should be smooth and
drop back to no more than 20.6 kPa (3 psi), after
engine returns to curb idle and brakes are applied to
prevent wheels from rotating.
(7)
Compare results of pressure test with analysis
chart.
Test Six - Transmission In Overdrive Fourth Gear
This test checks line pressure at the overdrive
clutch in fourth gear range. Use 300 psi Test Gauge
C-3293-SP for this test. The test should be performed
on the road or on a chassis dyno.
(1)
Remove tachometer; it is not needed for this test.
(2) Move 300 psi Gauge to overdrive clutch pres-
sure test port. Then remove other gauge and reinstall
test port plug.
(3) Lower vehicle.
(4) Turn OD switch on.(5) Secure test gauge so it can be viewed from
drivers seat.
(6) Start engine and shift into D range.
(7) Increase vehicle speed gradually until 3-4 shift
occurs and note gauge pressure.
(8) Pressure should be 524-565 kPa (76-82 psi)
with closed throttle and increase to 690-896 kPa
(100-130 psi) at 1/2 to 3/4 throttle. Note that pres-
sure can increase to around 965 kPa (140 psi) at full
throttle.
(9) Return to shop or move vehicle off chassis
dyno.
PRESSURE TEST ANALYSIS CHART
TEST CONDITION INDICATION
Line pressure OK during
any one testPump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear RangeOverdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and RLeakage in front clutch
area
Pressure OK in 2 but low
in R and 1Leakage in rear servo
Front servo pressure in 2 Leakage in servo; broken
servo ring or cracked
servo piston
Pressure low in all
positionsClogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speedGovernor pressure
solenoid valve system
fault. Refer to diagnostic
book.
Governor pressure low at
all mph figuresFaulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Lubrication pressure low
at all throttle positionsClogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Line pressure high Output shaft plugged,
sticky regulator valve
Line pressure low Sticky regulator valve,
clogged filter, worn pump
DRAUTOMATIC TRANSMISSION - 48RE 21 - 143
AUTOMATIC TRANSMISSION - 48RE (Continued)

DIAGNOSIS CHARTS
CONDITION POSSIBLE CAUSES CORRECTION
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)1. Fluid Level Low. 1. Add Fluid
2. Throttle Linkage Mis-adjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Mis-adjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component damaged.10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty. 11. Replace converter and flush cooler and
line before installing new converter.
21 - 146 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body. Replace
valve body (as assembly) if any valve or
bore is damaged. Clean and reassemble
correctly if all parts are in good condition.
7. Transmission Internal Component
Damaged.7. Remove and disassemble transmission.
Repair or replace failed components as
needed.
8. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return
to closed throttle at transmission.
5. Gearshift Linkage/Cable
Mis-adjusted.5. Adjust linkage/cable as described in
service section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
7. Governor Circuit Electrical Fault. 7. Test using DRBTscan tool and repair as
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
21 - 148 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO REVERSE (D RANGES
OK)1. Gearshift Linkage/Cable
Mis-adjusted/Damaged.1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)1. Governor Circuit Electrical Fault. 1. Test using DRBTscan tool and repair as
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor
plug.
3. Front Servo/Kickdown Band
Damaged/Burned.3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)1. Governor Circuit Electrical Fault. 1. Test with DRBTscan tool and repair as
required.
2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in
Bore.3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in
linkage.
DRAUTOMATIC TRANSMISSION - 48RE 21 - 149
AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.4. Check with DRBTscan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRBTscan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRBTscan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
21 - 154 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)