DODGE RAM 2001 Service Repair Manual

NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
front housing will have to be replaced if the coun-tershaft bearing race is loose, worn, or damaged.
The rear housing will have to be replaced if the
countershaft rear bearing race is loose, worn, or
damaged.
Fig. 44 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
Fig. 45 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
21 - 16 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth and final
polished with oil coated crocus cloth. Replace the
retainer seal if necessary.
Inspect the output shaft bearing retainer. Be sure
the U-shaped retainer is flat and free of distortion.
Replace the retainer if the threads are damaged, or if
the retainer is bent, or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, it will be necessary to
replace the front or rear housing as necessary. A
new countershaft bearing will be supplied with each
new housing for service use.
The countershaft bearings can be installed back-
wards if care is not exercised. The bearing roller cage
is a different diameter on each side. Be sure the
bearing is installed so the large diameter side of the
cage is facing the countershaft gear (Fig. 46). The
small diameter side goes in the bearing race.
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing if any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted, or brinnelled. Also
replace the bearing if the plastic bearing cage is
damaged or distorted.
Replace the thrust washer, wave washer, or thrust
plate if cracked, chipped, or worn. Replace the idler
gear if the teeth are chipped, cracked or worn thin.
Replace the shaft if worn, scored, or the bolt threads
are damaged beyond repair. Replace the support seg-
ment if cracked, or chipped and replace the idler
attaching bolts if the threads are damaged.
Shift Socket
Inspect the shift socket for wear or damage.
replace the socket if the roll pin, or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn, or cracked. Do not reuse the original
shift socket roll pin. Install a new pin during reas-
sembly. The socket roll pin is approximately is
approximately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all of the gears for worn, cracked, chipped,
or broken teeth. Also check condition of the bearing
bore in each gear. The bores should be smooth and
free of surface damage. Discoloration of the gear
bores is a normal occurrence and is not a reason for
replacement. Replace gears only when tooth damage
has occurred, or if the bores are brinnelled or
severely scored.
Inspect the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-
aged or bearing surfaces are deeply scored, worn, or
brinnelled.
ASSEMBLY
Gaskets are not used in this transmission. Sealers
are used at all case joints. Recommended sealers are
Mopar Gasket Maker for all case joints and Mopar
silicone sealer, or equivalent, for the input shaft
bearing retainer. Apply these products as indicated in
the assembly procedures.
NOTE: The transmission shift components must be
in Neutral position during assembly. This prevents
damaging to the synchro and shift components
when the housings are installed.
Fig. 46 Countershaft Bearings
1 - COUNTERSHAFT
2 - BEARING CAGE
BR/BEMANUAL - NV3500 21 - 17
MANUAL - NV3500 (Continued)

The 3-4, 1-2 and fifth-reverse synchro hub snap
rings can be fitted selectively. New snap rings are
available in 0.05 mm (0.0019 in.) thickness incre-
ments. Use thickest snap ring that will fit in each
snap ring groove.
SYNCHRONIZER
To assemble each synchro install the springs,
struts and detent balls one at a time as follows:
(1) Slide sleeve part way onto the hub. Leave
enough room to install the spring in the hub and the
strut in the hub groove.
(2) Install first spring in the hub, then install a
strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide sleeve onto the hub just far enough to
hold the first strut and spring in place.
(4) Place detent ball in the top of the strut, then
carefully work the sleeve over the ball to hold it in
place. A small flat blade screwdriver can be used to
press the ball into place while moving the sleeve over
it.
(5) Repeat procedure for the remaining springs,
struts and balls. Tape or a rubber band can be used
to temporarily secure each strut and ball as they are
installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 47).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears and bearings with rec-
ommended lubricant during assembly. Petroleum
jelly can be used to hold parts in place. Immerse
each synchro ring in lubricant before installation.
(1) Lubricate and install reverse gear needle bear-
ing on shaft (Fig. 48). Slide bearing up against shoul-
der on output shaft.
(2) Install reverse gear over needle bearing (Fig.
49).
(3) Install brass synchro ring on reverse gear (Fig.
50).
(4) Assemble fifth-reverse synchro hub, sleeve,
struts, springs and detent balls, if not previously
done.
CAUTION: One side of the hub has shoulders
around the hub bore, this side of the hub faces the
front of the shaft. One side of the sleeve is tapered
the tapered side faces the front of the shaft.
Fig. 47 Synchronizer Components
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
Fig. 48 Reverse Gear Bearing
1 - REVERSE GEAR BEARING
2 - SHOULDER
Fig. 49 Reverse Gear
1 - REVERSE GEAR
21 - 18 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(5) Start fifth-reverse synchro assembly on output
shaft splines by hand. Then seat synchro onto shaft
with shop press and Remover 6310-1 (Fig. 51).(6) Install the thickestnewfifth-reverse hub snap
ring (Fig. 52) that will fit in shaft groove. Verify snap
ring is seated in the groove.
NOTE: Snap rings are available in thicknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 in.).
(7) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 53).
Fig. 50 Reverse Gear Synchro
1 - REVERSE GEAR
2 - SYNCHRO RING
Fig. 51 Fifth-Reverse Synchro Assembly
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - REMOVER 6310-1
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
Fig. 52 Fifth-Reverse Synchro Hub Snap Ring
1 - FIFTH-REVERSE SYNCHRO ASSEMBLY
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
Fig. 53 Fifth Gear Synchro Ring
1 - FIFTH-SPEED SYNCHRO RING
2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
BR/BEMANUAL - NV3500 21 - 19
MANUAL - NV3500 (Continued)

(8) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 54).
Verify bearing is properly seated.
(9) Install fifth gear on shaft and onto bearing
(Fig. 55).
(10) Invert output shaft and set the shaft in Spe-
cial Tool 6310-1 so that fifth gear is seated on the
tool (Fig. 56).
(11) Install first gear bearing on output shaft (Fig.
56). Verify bearing is seated on shaft shoulder and is
properly joined.(12) Install first gear on shaft and over bearing
(Fig. 57). Verify bearing synchro cone is facing up as
shown.
Fig. 54 Fifth Gear Bearing
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 55 Fifth Gear
1 - FIFTH GEAR
2 - BEARING
Fig. 56 First Gear
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - SPECIAL TOOL 6310-1
4 - PRESS BLOCKS
Fig. 57 First Gear
1 - FIRST GEAR
2 - SPECIAL TOOL 6310-1
3 - BEARING
21 - 20 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(13) Install first gear synchro ring (Fig. 58).
(14) Assemble 1-2 synchro hub sleeve, springs,
struts and detent balls.
CAUTION: One side of the synchro sleeve is
marked First Gear Side. This side of the sleeve
must face first gear after installation.
(15) Start 1-2 synchro assembly on shaft by hand
(Fig. 59). Verify synchro sleeve is properly positioned.(16) Press 1-2 synchro onto output shaft using
suitable size pipe and shop press (Fig. 60).
CAUTION: Carefully align the synchro ring and
sleeve as hub the is being pressed onto the shaft.
The synchro ring can be cracked if it becomes mis-
aligned.
(17) Install interm ring.
(18) Install thickestnew1-2 synchro hub snap
ring (Fig. 61) that will fit in shaft groove. Verify snap
ring is seated in shaft groove.
NOTE: Snap rings are available in thicknesses from
1.80 mm to 2.00 mm (0.070 to 0.078 in.).
(19) Install second gear synchro ring in 1-2 syn-
chro hub and sleeve (Fig. 62). Verify synchro ring is
seated in sleeve.
(20) Install synchro friction cone and synchro cone
in synchro ring.
Fig. 58 First Gear Synchro Ring
1 - FIRST GEAR SYNCHRO RING
2 - SPECIAL TOOL 6310-1
3 - FIRST GEAR
Fig. 59 Starting 1-2 Synchro
1 - 1-2 SYNCHRO ASSEMBLY
2 - SPECIAL TOOL 6310-1
3 - FIRST GEAR SIDE
Fig. 60 Press 1-2 Synchro On Output Shaft
1 - PIPE TOOL
2 - SYNCHRO RING
3 - SPECIAL TOOL 6310-1
4 - 1-2 SYNCHRO ASSEMBLY
5 - PRESS RAM
BR/BEMANUAL - NV3500 21 - 21
MANUAL - NV3500 (Continued)

(21) Install second gear needle bearing on shaft
(Fig. 63).
(22) Install second gear onto shaft and bearing
(Fig. 64). Verify second gear is seated on synchro
components.(23) Install two-piece thrust washer with halves
seated in the shaft groove and washer lugs seated in
shaft lug bores (Fig. 65). Verify i.d. grooves and
markings noted during removal are facing the correct
direction.
Fig. 61 1-2 Synchro Hub Snap Ring
1 - 1-2 SYNCHRO
2 - SPECIAL TOOL 6310-1
3 - SYNCHRO SNAP RING
Fig. 62 Second Gear Synchro Ring
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - SPECIAL TOOL 6310-1
Fig. 63 Second Gear Bearing
1 - SECOND GEAR BEARING
2 - SPECIAL TOOL 6310-1
Fig. 64 Second Gear
1 - SPECIAL TOOL 6310-1
2 - 1-2 SYNCHRO ASSEMBLY
3 - BEARING
4 - SECOND GEAR
21 - 22 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(24) Start retaining ring around two-piece thrust
washer (Fig. 66). Verify locating dimple is between
thrust washer halves.
(25) Seat thrust washer retaining ring with plastic
mallet (Fig. 67).
Fig. 65 Two-Piece Thrust
1 - WASHER GROOVE IN SHAFT
2 - LUG BORE
3 - THRUST WASHER LUGS
4 - LUG BORE
5 - LUG
6 - WASHER HALF
Fig. 66 Retaining Ring
1 - THRUST WASHER RETAINING RING
2 - THRUST WASHER HALVES
3 - SECOND GEAR
4 - LOCATING DIMPLE
Fig. 67 Thrust Retainer
1 - PLASTIC MALLET
2 - THRUST WASHER RETAINING RING
BR/BEMANUAL - NV3500 21 - 23
MANUAL - NV3500 (Continued)

(26) Install third gear needle bearing on shaft (Fig.
68).
(27) Install third gear on shaft and bearing (Fig.
69).
(28) Install third speed synchro ring on third gear
(Fig. 70).
(29) Assemble 3-4 synchro hub, sleeve, springs,
struts and detent balls.CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the sleeve has grooves in it, this side of
sleeve faces the front of the shaft.
(30) Start 3-4 synchro hub on output shaft splines
by hand (Fig. 71).
Fig. 68 Third Gear Bearing
1 - THIRD GEAR BEARING
Fig. 69 Third Gear
1 - THIRD GEAR
2 - BEARING
Fig. 70 Third Gear Synchro Ring
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 71 3-4 Synchro Hub On Output Shaft
1 - GROOVED SIDE OF SLEEVE
2 - 3-4 SYNCHRO ASSEMBLY
21 - 24 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(31) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 72). Ver-
ify tool presses on hub as close to output shaft as
possible but does not contact the shaft splines.
(32) Install thickestnew3-4 synchro hub snap
ring (Fig. 73) that will fit in shaft groove. Verify snap
ring is seated in groove.
NOTE: Snap rings are available in thicknesses from
2.00 - 2.30 mm (0.078 - 0.090 in.).(33) Install output shaft bearing.
(34) Install output shaft bearing snap ring with
heavy duty snap ring pliers (Fig. 74). Verify snap
ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
(35) Verify position of synchro sleeves before pro-
ceeding (Fig. 75). Grooved side of 3-4 sleeve must be
facing forward. First gear side of 1-2 sleeve must be
facing first gear. Tapered side of fifth-reverse sleeve
must be facing forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube.
(2) Slide idler gear bearing on shaft (Fig. 76).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 76).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 76). Petroleum jelly can be used to
hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 77).
(6) Install snap ring in groove at rear of shaft (Fig.
77).
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
Fig. 72 Press 3-4 Synchro On Output Shaft
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 73 3-4 Synchro Hub Snap Ring
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 74 Output Shaft Bearing Snap
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
BR/BEMANUAL - NV3500 21 - 25
MANUAL - NV3500 (Continued)