4X4 DODGE RAM 1500 1998 2.G Repair Manual

(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)

STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
NOTE: The overdrive unit can be removed and ser-
viced separately. It is not necessary to remove the
entire transmission assembly to perform overdrive
unit repairs.
(1) Disconnect battery negative cable.
(2) Raise vehicle.
(3) Remove the transfer case skid plate (Fig. 12), if
equipped.(4) Disconnect and lower or remove necessary
exhaust components.
(5) Remove engine-to-transmission struts.
(6) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(7) Disconnect and remove the crankshaft position
sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain the sensor attaching bolts.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove torque converter access cover.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Disconnect wires from the transmission range
sensor and transmission solenoid connector.
(13) Disconnect gearshift cable (Fig. 13) from the
transmission.
Fig. 12 Transfer Case Skid Plate
1 - FRAME RAIL
2 - SKID PLATE
3 - BOLTS (6)
Fig. 13 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
21 - 158 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

(14) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(15) On 4X4 models, disconnect shift rod from
transfer case shift lever.
(16) Support rear of engine with safety stand or
jack.
(17) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(18) Remove bolts securing rear support and cush-
ion (Fig. 14) and (Fig. 15) to transmission and cross-
member and remove rear support.
(19) Remove bolts attaching crossmember to frame
and remove crossmember.
(20) On 4X4 models, remove transfer case with
transmission jack or aid of helper.
(21) Disconnect fluid cooler lines at transmission.
(22) Remove fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On 4X4
models, it will also be necessary to remove bolt
attaching transfer case vent tube to converter hous-
ing (Fig. 16).
(23) Remove all converter housing bolts.
(24) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(25) Lower transmission and remove assembly
from under the vehicle.
(26) To remove torque converter, remove C-clamp
from edge of bell housing and carefully slide torque
converter out of the transmission.
Fig. 14 Engine Rear Mount - 4X2 Automatic
Transmission
1 - ENGINE REAR MOUNT
2 - BOLT
3 - NUT
4 - THROUGH BOLT NUT
5 - TRANSMISSION
Fig. 15 Engine Rear Mount - 4X4 Automatic
Transmission
1 - TRANSMISSION
2 - ENGINE REAR MOUNT
3 - BOLT
Fig. 16 Fill Tube Attachment
1 - TRANSFER CASE VENT TUBE
2 - FILL TUBE (V8)
3 - TUBE SEAL
4 - FILL TUBE (V6)
DRAUTOMATIC TRANSMISSION - 48RE 21 - 159
AUTOMATIC TRANSMISSION - 48RE (Continued)

(11) Remove and discard the oil filter seal from the
bottom of the oil pump.
(12) If replacing the cooler return filter, use Oil
Filter Wrench 8321 to remove the filter from the
transmission.
(13) Dispose of used trans fluid and filter(s) prop-
erly.
INSPECTION
Inspect bottom of pan and magnet for excessive
amounts of metal. A light coating of clutch material
on the bottom of the pan does not indicate a problem
unless accompanied by a slipping condition or shift
lag. If fluid and pan are contaminated with excessive
amounts of debris, refer to the diagnosis section of
this group.
CLEANING
(1) Using a suitable solvent, clean pan and mag-
net.
(2) Using a suitable gasket scraper, clean original
sealing material from surface of transmission case
and the transmission pan.
INSTALLATION
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(1) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.(2) Place replacement filter in position on valve
body and into the oil pump.
(3) Install screw to hold filter to valve body (Fig.
67). Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(4) Install new cooler return filter onto the trans-
mission, if necessary. Torque the filter to 14.12 N´m
(125 in.lbs.).
(5) Place bead of MopartRTV sealant onto the
transmission case sealing surface.
(6) Place pan in position on transmission.
(7) Install bolts to hold pan to transmission.
Tighten bolts to 11.8 N´m (105 in. lbs.) torque.
(8) Lower vehicle and fill transmission with
MopartATF +4.
STANDARD PROCEDURE - TRANSMISSION
FILL
To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:
(1) Remove dipstick and insert clean funnel in
transmission fill tube.
(2) Add following initial quantity of MopartAT F
+4 to transmission:
(a) If only fluid and filter were changed, add10
pints (5 quarts)of ATF +4 to transmission.
(b) If transmission was completely overhauled
and the torque converter was replaced or drained,
add24 pints (12 quarts)of ATF +4 to transmis-
sion.
(3) Check the transmission fluid (Refer to 21 -
TRANSMISSION/AUTOMATIC - RFE/FLUID -
STANDARD PROCEDURE) and adjust as required.
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE
(1) Engine starts must be possible with shift lever
in PARK or NEUTRAL positions only. Engine starts
must not be possible in any other gear position.
(2) With the shift lever in the:
(a) PARK position - Apply upward force on the
shift arm and remove pressure. Engine starts must
be possible.
(b) PARK position - Apply downward force on
the shift arm and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
(d) NEUTRAL position - Engine running and
brakes applied, apply upward force on the shift
arm. Transmission shall not be able to shift from
neutral to reverse.
Fig. 67 Transmission Filters - 4X4 Shown
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
21 - 368 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
FLUID AND FILTER (Continued)

LATCH STRIKER - INSTALLATION . . 23-17,23-23,
23-33
LATCH STRIKER - REMOVAL . 23-16,23-23,23-33
LATCH STRIKER / SECONDARY CATCH -
INSTALLATION.......................23-48
LATCH STRIKER / SECONDARY CATCH -
REMOVAL..........................23-47
LD & HD EXCEPT 4X4 HD -
INSTALLATION, ALL..................19-14
LD & HD EXCEPT 4X4 HD - REMOVAL,
ALL ...............................19-14
LD FRONT - INSTALLATION, PROPELLER
SHAFT...............................3-7
LD FRONT - REMOVAL, PROPELLER
SHAFT...............................3-6
LEAD - DIAGNOSIS AND TESTING,
TIRE/VEHICLE........................22-8
LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING FLUID....21-144,21-318
LEAK - DIAGNOSIS AND TESTING,
ENGINE OIL................9-152,9-220,9-64
LEAK DETECTION ASSY - DESCRIPTION,
NATURAL VAC.......................25-23
LEAK DETECTION ASSY - INSTALLATION,
NATURAL VAC.......................25-25
LEAK DETECTION ASSY - OPERATION,
NATURAL VAC.......................25-23
LEAK DETECTION ASSY - REMOVAL,
NATURAL VAC.......................25-24
LEAK DETECTION PUMP - DESCRIPTION . . 25-13
LEAK DETECTION PUMP - INSTALLATION . 25-16
LEAK DETECTION PUMP - OPERATION....25-14
LEAK DETECTION PUMP - REMOVAL.....25-16
LEAKAGE - DIAGNOSIS AND TESTING,
CYLINDER COMBUSTION PRESSURE . 9-186,9-8,
9-93
LEAKAGE - DIAGNOSIS AND TESTING,
INTAKE MANIFOLD..............9-159,9-225
LEAKAGE - DIAGNOSIS AND TESTING,
PUMP.............................19-40
LEAKS - DIAGNOSIS AND TESTING,
CHARGE AIR COOLER SYSTEM.........11-16
LEAKS - DIAGNOSIS AND TESTING,
COOLING SYSTEM - TESTING.............7-5
LEAKS - DIAGNOSIS AND TESTING,
HIGH-PRESSURE FUEL LINE............14-58
LEAKS - DIAGNOSIS AND TESTING,
INTAKE MANIFOLD....................9-72
LEAKS - DIAGNOSIS AND TESTING,
REAR SEAL AREA...........9-137,9-209,9-65
LEAKS - DIAGNOSIS AND TESTING,
REFRIGERANT SYSTEM...............24-44
LEAKS - DIAGNOSIS AND TESTING,
WATER .............................23-1
LEAKS - STANDARD PROCEDURE,
REPAIRING.........................22-10
LEARN - STANDARD PROCEDURE,
DRIVE.............................8E-23
LEARN - STANDARD PROCEDURE, TCM
QUICK.............................8E-23
LEFT CYLINDER HEAD - INSTALLATION . . . 9-112
LEFT CYLINDER HEAD - REMOVAL.......9-108
LEFT REAR CABLE - INSTALLATION.......5-39
LEFT REAR CABLE - REMOVAL...........5-38
LENS REPLACEMENT - STANDARD
PROCEDURE, MODULE................8M-3
LEVEL - DIAGNOSIS AND TESTING,
EFFECTS OF INCORRECT FLUID . . 21-201,21-366
LEVEL - STANDARD PROCEDURE,
BRAKE FLUID........................5-23
LEVEL - STANDARD PROCEDURE,
ENGINE OIL.........................9-292
LEVEL - STANDARD PROCEDURE,
REFRIGERANT OIL...................24-69
LEVEL CHECK - STANDARD
PROCEDURE, COOLANT................7-17
LEVEL CHECK - STANDARD
PROCEDURE, FLUID...........21-202,21-366
LEVEL CHECKING - STANDARD
PROCEDURE, POWER STEERING FLUID
. . . 19-43
LEVEL SENDING UNIT / SENSOR -
DESCRIPTION, FUEL
..............14-57,14-6
LEVEL SENDING UNIT / SENSOR -
INSTALLATION, FUEL
..................14-7
LEVEL SENDING UNIT / SENSOR -
OPERATION, FUEL
................14-57,14-6
LEVEL SENDING UNIT / SENSOR -
REMOVAL, FUEL
......................14-7LEVEL SWITCH - DESCRIPTION,
WASHER FLUID......................8R-9
LEVEL SWITCH - INSTALLATION,
WASHER FLUID.....................8R-11
LEVEL SWITCH - OPERATION, WASHER
FLUID..............................8R-9
LEVEL SWITCH - REMOVAL, WASHER
FLUID.............................8R-10
LEVER - ADJUSTMENT, SHIFT . . . 21-446,21-481
LEVER - INSTALLATION, GEAR SHIFT.....19-12
LEVER - INSTALLATION, SHIFT . . . 21-445,21-480
LEVER - REMOVAL, GEAR SHIFT........19-12
LEVER - REMOVAL, SHIFT......21-444,21-479
LEVER KNOB RELEASE - INSTALLATION,
TILT ...............................19-16
LEVER KNOB RELEASE - REMOVAL, TILT . . 19-16
LICENSE PLATE LAMP - INSTALLATION . . . 8L-17
LICENSE PLATE LAMP - REMOVAL.......8L-17
LICENSE PLATE LAMP UNIT -
INSTALLATION.......................8L-17
LICENSE PLATE LAMP UNIT - REMOVAL . . 8L-17
LID - INSTALLATION, CENTER SEAT
BACK..............................23-79
LID - INSTALLATION, UNDER SEAT
STORAGE BIN.......................23-80
LID - REMOVAL, CENTER SEAT BACK....23-79
LID - REMOVAL, UNDER SEAT STORAGE
BIN ...............................23-80
LIFTERS/TAPPETS - CLEANING, SOLID....9-279
LIFTERS/TAPPETS - INSPECTION, SOLID . . . 9-279
LIFTERS/TAPPETS - INSTALLATION,
SOLID.............................9-280
LIFTERS/TAPPETS - REMOVAL, SOLID....9-279
LIGHT DUTY FRONT FRAME RAIL TIP
REPLACEMENT - STANDARD
PROCEDURE.........................13-4
LIGHTER OUTLET - DESCRIPTION,
CIGAR...........................8W-97-2
LIGHTER OUTLET - DIAGNOSIS AND
TESTING, CIGAR...................8W-97-2
LIGHTER OUTLET - OPERATION, CIGAR . 8W-97-2
LIMITING VALVE - DESCRIPTION, FUEL
PRESSURE.........................14-61
LIMITING VALVE - INSTALLATION, FUEL
PRESSURE.........................14-61
LIMITING VALVE - OPERATION, FUEL
PRESSURE.........................14-61
LIMITING VALVE - REMOVAL, FUEL
PRESSURE.........................14-61
LINE - DESCRIPTION, A/C DISCHARGE....24-56
LINE - DESCRIPTION, LIQUID...........24-65
LINE - DESCRIPTION, REFRIGERANT.....24-42
LINE - DESCRIPTION, SUCTION.........24-70
LINE - INSTALLATION, LIQUID..........24-66
LINE - REMOVAL, LIQUID..............24-65
LINE AND TERMINAL REPAIR -
STANDARD PROCEDURE, GRID..........8G-4
LINE COUPLER - DESCRIPTION,
REFRIGERANT.......................24-67
LINE COUPLER - INSTALLATION,
REFRIGERANT.......................24-68
LINE COUPLER - OPERATION,
REFRIGERANT.......................24-67
LINE COUPLER - REMOVAL,
REFRIGERANT.......................24-68
LINE LEAKS - DIAGNOSIS AND TESTING,
HIGH-PRESSURE FUEL................14-58
LINE PRESSURE (LP) SENSOR -
DESCRIPTION......................21-382
LINE PRESSURE (LP) SENSOR -
INSTALLATION......................21-383
LINE PRESSURE (LP) SENSOR -
OPERATION........................21-383
LINE PRESSURE (LP) SENSOR -
REMOVAL.........................21-383
LINES - DESCRIPTION, FUEL.......14-57,14-7
LINES - DESCRIPTION, VACUUM........25-22
LINES - INSTALLATION, FUEL...........14-60
LINES - OPERATION, FUEL.............14-57
LINES - OPERATION, REFRIGERANT......24-42
LINES - REMOVAL, FUEL..............14-58
LINK - INSTALLATION, DRAG...........19-36
LINK - REMOVAL, DRAG...............19-36
LINK CONNECTOR - DESCRIPTION, DATA
. . 8E-3
LINK CONNECTOR - OPERATION, DATA
....8E-3
LINKAGE - INSTALLATION
...............6-12
LINKAGE - LINK/COIL - DESCRIPTION
....19-34
LINKAGE - REMOVAL
..................6-12LINKAGE, SPECIAL TOOLS - STEERING . . . 19-35
LINK/COIL - DESCRIPTION, GEAR........19-20
LINK/COIL - DESCRIPTION, LINKAGE.....19-34
LINK/COIL - INSTALLATION, GEAR.......19-21
LINK/COIL - OPERATION, GEAR.........19-20
LINK/COIL - REMOVAL, GEAR...........19-20
LINK/COIL SUSPENSION - STANDARD
PROCEDURE, ALIGNMENT...............2-5
LIQUID LINE - DESCRIPTION...........24-65
LIQUID LINE - INSTALLATION...........24-66
LIQUID LINE - REMOVAL..............24-65
LOAD FLOOR - INSTALLATION..........23-72
LOAD FLOOR - REMOVAL..............23-71
LOAD FLOOR SUPPORT CYLINDER -
INSTALLATION.......................23-72
LOAD FLOOR SUPPORT CYLINDER -
REMOVAL..........................23-72
LOCATION - DESCRIPTION, CONNECTOR/
GROUND/SPLICE...................8W-91-1
LOCATIONS - SPECIFICATIONS, SEALER . 23-102
LOCATIONS - SPECIFICATIONS,
STRUCTURAL ADHESIVE..............23-112
LOCATIONS - SPECIFICATIONS, WELD . . . 23-120
LOCK - STANDARD PROCEDURE,
HYDROSTATIC..................9-190,9-240
LOCK CYLINDER - DIAGNOSIS AND
TESTING, IGNITION SWITCH AND KEY....19-11
LOCK CYLINDER - INSTALLATION.......23-24
LOCK CYLINDER - REMOVAL.............23-24
LOCK MOTOR - DESCRIPTION, DOOR.....8N-4
LOCK MOTOR - DIAGNOSIS AND
TESTING, DOOR......................8N-4
LOCK MOTOR - OPERATION, DOOR.......8N-4
LOCK SWITCH - DIAGNOSIS AND
TESTING, POWER.....................8N-4
LOCK SWITCH - INSTALLATION, POWER . . . 8N-4
LOCK SWITCH - REMOVAL, POWER......8N-4
LOCKING RETRACTOR - DESCRIPTION,
AUTOMATIC........................8O-14
LOCKING RETRACTOR - OPERATION,
AUTOMATIC........................8O-14
LOCKS - DESCRIPTION, POWER.........8N-1
LOCKS - DIAGNOSIS AND TESTING,
POWER.............................8N-3
LOCKS - OPERATION, POWER...........8N-2
LOOP ADJUSTER - INSTALLATION, SEAT
BELT TURNING......................8O-55
LOOP ADJUSTER - REMOVAL, SEAT
BELT TURNING......................8O-55
LOOP BRACKETS - INSTALLATION, SEAT
BACK REAR - FOOTMANS..............23-85
LOOP BRACKETS - REMOVAL, SEAT
BACK REAR - FOOTMANS..............23-85
LOW FUEL INDICATOR - DESCRIPTION . . . 8J-30
LOW FUEL INDICATOR - OPERATION.....8J-30
LOWER BALL JOINT - DIAGNOSIS AND
TESTING........................2-19,2-34
LOWER BALL JOINT - INSTALLATION . 2-20,2-35
LOWER BALL JOINT - REMOVAL.....2-19,2-35
LOWER CONTROL ARM BUSHINGS -
2WD (LD) - INSTALLATION..............2-15
LOWER CONTROL ARM BUSHINGS -
2WD (LD) - REMOVAL.................2-13
LOWER CONTROL ARM BUSHINGS -
4WD (LD) - INSTALLATION..............2-14
LOWER CONTROL ARM BUSHINGS -
4WD (LD) - REMOVAL.................2-13
LOWER SURROUND - INSTALLATION,
INSTRUMENT PANEL..................23-59
LOWER SURROUND - REMOVAL,
INSTRUMENT PANEL..................23-59
LOWER SUSPENSION ARM -
INSTALLATION........................2-38
LOWER SUSPENSION ARM - REMOVAL....2-38
LOWER TRIM - INSTALLATION,
B-PILLAR...........................23-64
LOWER TRIM - INSTALLATION,
C-PILLAR...........................23-67
LOWER TRIM - REMOVAL, B-PILLAR.....23-63
LOWER TRIM - REMOVAL, C-PILLAR.....23-66
LOW/REVERSE CLUTCH - ASSEMBLY....21-385
LOW/REVERSE CLUTCH - CLEANING
....21-385
LOW/REVERSE CLUTCH - DISASSEMBLY
. 21-384
LOW/REVERSE CLUTCH - INSPECTION
. . 21-385
LUBRICANTS - DESCRIPTION, ENGINE
OIL
.................................0-1
LUBRICATION - DESCRIPTION
.....9-150,9-220,
9-289,9-61
DRINDEX 19
Description Group-Page Description Group-Page Description Group-Page