boot DODGE RAM 1500 1998 2.G Owner's Guide

WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) While holding the centered clockspring rotor
and case stationary in relation to each other, care-
fully slide the clockspring down over the steering col-
umn upper shaft.
(2) Align and seat the hole in the locating tab at
the eleven o'clock position on the clockspring case
over the locating pin on the multi-function switch
mounting housing (Fig. 20).
(3) Install and tighten the two screws that secure
the clockspring to the multi-function switch mount-
ing housing. Tighten the screws to 2 N´m (20 in.
lbs.).
(4) Reconnect the two instrument panel wire har-
ness connectors for the clockspring to the two connec-
tor receptacles below the steering column on the back
of the clockspring housing.
(5) Position the lower shroud onto the steering col-
umn.
(6) From below the steering column, install and
tighten the one center screw that secures the lower
shroud to the steering column lock housing. Tighten
the screw to 2 N´m (20 in. lbs.).(7) Position the upper shroud onto the steering col-
umn. If the vehicle is equipped with an automatic
transmission, be certain to engage the gearshift lever
gap hider into the openings in the right side of the
upper and lower shrouds.
(8) Align the snap features on the upper shroud
with the receptacles on the lower shroud and apply
hand pressure to snap them together.
(9) From below the steering column, install and
tighten the two screws that secure the upper shroud
to the lower shroud. Tighten the screws to 2 N´m (20
in. lbs.).
(10) If the vehicle is equipped with the optional tilt
steering column, align the steering column tilt knob
with the tilt adjuster mechanism lever located on the
left side of the column just below the multi-function
switch control stalk and, using hand pressure, push
the knob firmly onto the lever.
(11) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(12) If a new clockspring has been installed,
remove the plastic locking pin that is securing the
clockspring rotor to the clockspring case to maintain
clockspring centering.
NOTE: When reinstalling the steering wheel, be cer-
tain to index the yellow rubber booted engagement
dowel on the upper surface of the clockspring rotor
between the two fins cast into the lower surface of
the steering wheel armature hub.
(13) Reinstall the steering wheel onto the steering
column. (Refer to 19 - STEERING/COLUMN/STEER-
ING WHEEL - INSTALLATION).
(14) Reconnect the steering wheel wire harness
connectors to the upper clockspring connector recep-
tacles. Be certain that the steering wheel wire har-
ness is routed between the steering wheel back trim
cover and the steering wheel armature.
(15) Reinstall the driver airbag onto the steering
wheel. (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - INSTALLATION).
8O - 22 RESTRAINTSDR
CLOCKSPRING (Continued)

(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear.
(2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 28
N´m (250 in. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
STEERING WHEEL
REMOVAL
(1) Disable and remove the driver's side air-
bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 61 N´m (45 ft. lbs.).
(3) Install the driver's side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DRCOLUMN 19 - 15
LOWER STEERING COUPLING (Continued)

LINKAGE - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
LINKAGE - INDEPENDENT FRONT
SUSPENSION
DIAGNOSIS AND TESTING - OUTER TIE ROD
END ................................32TIE ROD END
REMOVAL - OUTER TIE ROD END..........32
INSTALLATION - OUTER TIE ROD END......33
LINKAGE - INDEPENDENT
FRONT SUSPENSION
DIAGNOSIS AND TESTING - OUTER TIE ROD
END
NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.
(2) Remove the front tires.
(3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.
(4) Position indicator plunger on the topside of the
outer tie rod end.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the outer tie rod
end.
(5) Position a pry bar in order to pry downwards
on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).
TIE ROD END
REMOVAL - OUTER TIE ROD END
NOTE: Do not twist the boot anytime during
removal or installation.
(1) Loosen the jam nut.
(2) Remove the outer tie rod end nut from the ball
stud.
(3) Separate the tie rod ball stud from the knuckle
with Remover 8677 (Fig. 1).
(4) Unthread the outer tie rod end from the inner
tie rod.
Fig. 1 TIE ROD SEPARATION
1 - TIE ROD END
2 - SPECIAL TOOL 8677
19 - 32 LINKAGE - INDEPENDENT FRONT SUSPENSIONDR

INSTALLATION - OUTER TIE ROD END
NOTE: Do not twist the boot at anytime during
removal or installation.
(1) Thread the outer tie rod end onto the inner tie
rod, to it's original position (Fig. 2).
(2) Install the outer tie rod end into the steering
knuckle (Fig. 2).
(3) Tighten the ball stud nut on the ball stud to 61
N´m (45 ft. lbs.) then an additional 90É.
(4) Set wheel toe pattern, (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
(5) Tighten jam nut to 75 N´m (55 ft. lbs.) (Fig. 2).
Fig. 2 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
DRLINKAGE - INDEPENDENT FRONT SUSPENSION 19 - 33
TIE ROD END (Continued)

DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incor-
rect lubricant level check. Leaks can occur at the
mating surfaces of the gear case, adaptor or exten-
sion housing, or from the front/rear seals. A sus-
pected leak could also be the result of an overfill
condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Shift component damage or damaged clutch pres-
sure plate or disc are additional probable causes of
increased shift effort. Worn/damaged pressure plate
or disc can cause incorrect release. If clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear and bearing
damage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Raise vehicle on hoist.
(6) Remove skid plate, if equipped.
(7) Drain lubricant if transmission will be disas-
sembled for service.
(8) Mark propeller shaft/shafts and companion
flange yoke/yokes for installation reference and
remove propeller shaft/shafts.
(9) Disconnect harness from clips on transmission
housing.
(10) Remove transfer case linkage if equipped.
(11) Remove transfer case mounting nuts and
remove transfer case if equipped.
(12) Remove slave cylinder mounting nut and
remove cylinder (Fig. 2).
Fig. 2 SLAVE CYLINDER
1 - MOUNTING NUTS
2 - SLAVE CYLINDER
DRMANUAL TRANSMISSION - NV3500 21 - 3
MANUAL TRANSMISSION - NV3500 (Continued)

The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents 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 synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether the
driver is up-shifting or down-shifting). The synchro-
nizer does this by having the synchronizer hub
splined to the mainshaft, or the countershaft in some
cases, and moving the blocker ring into contact with
the gear's friction cone. As the blocker ring and fric-
tion 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 syn-
chronizer 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 synchronizer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incor-
rect lubricant level check. A correct lubricant level
check can only be made when the vehicle is level.
Also allow the lubricant to settle for a minute or so
before checking. These recommendations will ensure
an accurate check and avoid an underfill or overfill
condition. Always check the lubricant level after any
addition of fluid to avoid an incorrect lubricant level
condition.
Leaks can occur at the mating surfaces of the gear
case, adaptor or extension housing, or from the front/
rear seals. A suspected leak could also be the result
of an overfill condition. Leaks at the rear of the
extension or adapter housing will be from the hous-
ing oil seals. Leaks at component mating surfaces
will probably be the result of inadequate sealer, gaps
in the sealer, incorrect bolt tightening or use of a
non-recommended sealer. A leak at the front of the
transmission will be from either the front bearing
retainer or retainer seal. Lubricant may be seen drip-
ping from the clutch housing after extended opera-
tion. If the leak is severe, it may also contaminate
the clutch disc causing the disc to slip, grab and or
chatter.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants isnoise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds. Severe highly audible transmission noise is
generally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant
will promote rapid wear of gears, synchros, shift
rails, forks and bearings. The overheating caused by
a lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Shift transmission into Neutral.
(2) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(3) Remove shift lever extension from shift tower
and lever assembly.
(4) Remove shift tower bolts (Fig. 2).
Fig. 2 SHIFT TOWER
1 - SHIFT TOWER
2 - SHIFTER
3 - BOLTS
21 - 44 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

INSTALLATION
NOTE: If a new transmission is being installed, use all
components supplied with the new transmission. For
example, if a new shift tower is supplied with the new
transmission, do not re-use the original shift tower.
(1) Apply light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
the following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
(4) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(5)
Move transmission forward and start input shaft
in release bearing, clutch disc and pilot bushing.
(6)Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after input shaft has entered clutch disc.
(7) Install transmission bolts and tighten to 108
N´m (80 ft. lbs.).
(8) Install transmission mount on transmission or
rear crossmember.
(9) Install rear crossmember.
(10) Remove transmission jack and engine support
fixture.
(11) Position transmission harness wires in clips
on shift cover.
(12) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(13) Connect speed sensor and backup light switch
wires.
TWO WHEEL DRIVE
(1) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(2) Align and install propeller shaft.
(3) Lower vehicle.
(4) Clean the mating surfaces of shift tower, isola-
tor plate and shift cover with suitable wax and
grease remover.
(5) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(6) Install the isolator plate onto the shift cover,
metal side down.
(7) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.(8) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(9) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(10) Install the shift lever extension onto the shift
tower and lever assembly.
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install transfer case shift mechanism on trans-
mission.
(2) Install transfer case on transmission jack.
Secure transfer case to jack with safety chains.
(3) Raise jack and align transfer case input gear
with transmission mainshaft.
(4) Move transfer case forward and seat it on
adapter.
(5) Install transfer case nuts and tighten to:
²If 3/8 studs 41-47 N´m (30-35 ft. lbs.).
²If 5/16 studs 30-41 N´m (22-30 ft. lbs.).
(6) Install transfer case shift mechanism to side of
transfer case.
(7) Connect transfer case shift lever to range lever
on transfer case.
(8) Align and connect propeller shafts.
(9) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(10) Install transfer case skid plate, if equipped
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(11) Install exhaust system components.
(12) Lower vehicle.
(13) Clean the mating surfaces of shift tower, iso-
lator plate and shift cover with suitable wax and
grease remover.
(14) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(15) Install the isolator plate onto the shift cover,
metal side down.
(16) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(17) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(18) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(19) Install the shift lever extension onto the shift
tower and lever assembly.
(20) Install shift lever boot and bezel.
(21) Connect battery negative cable.
21 - 80 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of Mopar silicone sealer or
equivalent to outer edge of each new plug.
(2) Position each plug in bore and tap into place
with hammer and punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab.
(2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift mechanism
cover and gear case with wax and grease remover.
(2)
Apply a small amount of Mopar silicone sealer or
equivalent to sealing surface of shift mechanism cover.
CAUTION: Do not use an excessive amount sealer.
Excess can squeezed into gear case and could
block lubricant feed holes in time.
(3) Lubricate synchro sleeves with CastroltSyn-
torq gear lubricant or equivalent. Then apply light
coat of petroleum jelly to shift fork contact surfaces.
(4) Verify shift fork pads (Fig. 138) are secure.
(5) Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
(6) Align and seat shift mechanism cover on trans-
mission.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
(7) Apply Mopar Lock N' Seal or equivalent to
threads of shift cover bolts.
(8) Install shift cover mechanism bolts and tighten
to 27-31 N´m (216-276 in. lbs.).(9)
Apply sealer to backup lamp switch. Install switch
into cover and tighten to 22-34 N´m (193-265 in. lbs.).
(10) Install vent assembly if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
(11) Install transmission.
SHIFT COVER
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission shift cover.
(5) Remove the shift tower and isolator plate from
the transmission shift cover.
INSTALLATION
(1) Clean the mating surfaces of shift tower, isola-
tor plate and shift cover with suitable wax and
grease remover.
(2) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(3) Install the isolator plate onto the shift cover,
metal side down.
(4) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(5) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(6) Install bolts to hold the shift tower to the iso-
lator plate and the shift cover. Tighten the shift
tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(7) I
nstall shift lever extension, shift boot and bezel.
Fig. 137 EXPANSION PLUG LOCATION
1 - EXPANSION PLUGS
Fig. 138 SHIFT FORK PAD
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
DRMANUAL TRANSMISSION - NV4500 21 - 87
SHIFT MECHANISM (Continued)

(2) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(3) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(4) Remove the shift tower and isolator plate from
the transmission gear case.
(5) Raise and support vehicle.
(6) Remove skid plate, if equipped.
(7) Mark propeller shaft/shafts and axle yokes for
installation reference.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system as nec-
essary.
(10) Disconnect wires at backup light switch.
(11) Support engine with adjustable safety stand
and wood block.
(12) If transmission is to be disassembled for
repair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission (Fig. 3).
(13) Remove clutch slave cylinder splash shield, if
equipped.
(14) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(15)
Remove wire harness from clips on transmission.
TWO WHEEL DRIVE
(1) Remove bolts/nuts mounting transmission to
the rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmember.
(4) Remove transmission clutch housing bolts at
the engine block.
(5) Slide transmission and jack rearward until
input shaft clears clutch disc and pressure plate.
(6) 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.
(2) Support and secure transfer case with safety
chains to a transmission jack.
(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 bolts/nuts attaching transmission
mount to rear crossmember.
(8) Remove rear crossmember bolts and pry out
crossmember.
(9) Remove transmission clutch housing bolts at
the engine block.
(10) Move transmission rearward until input shaft
clears clutch disc.
(11) Lower transmission and remove it from under
vehicle.
DISASSEMBLY
NOTE: Use Fixture 8241 for moving and handling
the transmission. The fixture supports the transmis-
sion at the center of gravity in order to ease mount-
ing the transmission into the build fixture.
(1)
Mount the transmission into Fixture 8230 (Fig. 4).
Fig. 3 NV5600 DRAIN BOLT
1 - PTO COVER
2 - DRAIN BOLT
Fig. 4 TRANSMISSION FIXTURE
1 - FIXTURE
2 - TRANSMISSION
DRMANUAL TRANSMISSION - NV5600 21 - 91
MANUAL TRANSMISSION - NV5600 (Continued)

(10) Install reverse countershaft rear bearing onto
the countershaft reverse gear assembly with Installer
C-4652 and Handle C-4171.
(11) Install reverse idler gear rear bearing, bearing
spacer, front bearing, and front thrust washer onto
the idler gear shaft.
(12) Install idler and reverse countershaft gears
together (Fig. 90).
(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171, if necessary. The
oil feed hole must be at the 12 o'clock position when
installed.
(2) On 4X2 vehicles, install extension housing seal
with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
Fig. 90 REVERSE IDLER AND COUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 91 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 92 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
21 - 120 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)