DODGE RAM 2001 Service Repair Manual

SHIFT PATTERN
The shift pattern is in a modified H pattern (Fig.
2). Overdrive fifth and reverse gears are in line and
outboard of the first through fourth gear positions.
GEAR RATIOS
GEAR RATIO
FIRST 5.61:1
SECOND 3.04:1
THIRD 1.67:1
FOURTH 1.00:1
FIFTH 0.75:1
REVERSE 5.04:1
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 3).
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.
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 slowdown the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer 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 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 synchronizer.
DIAGNOSIS AND TESTING - MANUAL
TRANSMISSION
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 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 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.
Fig. 2 NV4500
Fig. 3 Identification Tag Location
1 - PTO COVER
2 - I.D. TAG
21 - 46 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

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.
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 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 breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(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. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
Fig. 4 NV4500 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
BR/BEMANUAL - NV4500 21 - 47
MANUAL - NV4500 (Continued)

(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.
(10) Remove clutch slave cylinder splash shield, if
equipped.
(11) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever. This
reduces pressure on lever and release bearing mak-
ing transmission removal/installation easier. Cylinder
does not have to be removed completely.
(12) Remove transmission bolts from clutch hous-
ing.
(13) Move transmission rearward until input shaft
clears clutch disc and release bearing.
(14) Lower transmission and remove it from under
vehicle.
DISASSEMBLY
EXTENSION/ADAPTER HOUSING
(1) Raise and support vehicle.
(2) Remove rear propeller shaft.
(3) Support transmission with a transmission jack.
(4) Remove engine rear support. Refer to 9 Engine
for procedures.
(5) Remove transfer case, if equipped.
(6) Remove bolts attaching extension/adapter hous-
ing to gear case (Fig. 6).
(7) Remove extension/adapter housing (Fig. 7).
There is one alignment dowel in the gear case and
one in the extension/adapter housing.
(8) Remove rubber spline seal from end of main-
shaft (Fig. 8). The seal is used to prevent lubricant
loss during shipping and does not have to be replaced
if damaged.
Fig. 5 Transfer Case Shift Mechanism-Typical
1 - TRANSMISSION
2 - TRANSFER CASE SHIFT MECHANISM
Fig. 6 Extension/Adapter Housing Bolts
1 - EXTENSION HOUSING
2 - BOLTS
21 - 48 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

FIFTH GEAR NUT
(1) Remove extension/adapter housing.
(2) Loosen fifth gear clamp nut clamping screw
approximately 1 1/2 turns.
(3)
Install nut Wrench 6743 on fifth gear nut (Fig. 9).
NOTE: Wrench only fits one way on nut. Be sure
wrench is fully engaged in nut slots and is not
cocked.
(4) Install splined Socket 6993 4X2 Socket 6984
4X4 to retain mainshaft while removing the fifth
gear nut.
(5) Install breaker bar in socket wrench (Fig. 9)
NOTE: Wedge breaker bar handle against work-
bench. Purpose of socket wrench and breaker baris to prevent mainshaft from turning while nut is
loosened.
(6) Remove fifth gear nut, then remove belleville
washer from mainshaft.
FIFTH GEAR
(1) Remove roll pins that secure countershaft fifth
gear shift fork to shift rail with pin punch (Fig. 10).
Roll pins are driven out from bottom of fork and not
from top.
(2) Remove snap ring that secures fifth gear clutch
hub and gear on countershaft (Fig. 11).
(3) Remove countershaft fifth gear clutch gear and
stop ring.
(4) Remove fifth gear shift fork and gear assembly.
Remove assembly by tapping fork off rail with plastic
mallet.
(5) Remove fifth gear shift fork from sleeve.
(6) Remove sleeve, struts, and strut springs from
countershaft fifth gear hub, if necessary.
(7) Remove countershaft fifth gear needle bearing
assembly (Fig. 12).
(8) Remove cone shaped rear bearing thrust
washer from end of countershaft (Fig. 13). Note posi-
tion of washer for assembly reference. Also note that
washer bore has notch for locating pin.
(9) Remove and retain thrust washer locating pin
from countershaft.
(10) Remove mainshaft overdrive fifth gear with
Puller Tool Set 6444.
Fig. 7 Extension/Adapter Housing
1 - GEAR CASE
2 - EXTENSION HOUSING
Fig. 8 Mainshaft Spline Seal
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 9 Fifth Gear Nut
1 - WRENCH 6443/6743
2 - FIFTH GEAR NUT
3 - SCOCKET 6993/6984
BR/BEMANUAL - NV4500 21 - 49
MANUAL - NV4500 (Continued)

(11) Position first Puller Jaw 6459 or 6820 on gear
(Fig. 14).
(12) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 4X2 vehicles or 6444-4 4X4 vehicles
(Fig. 15).
(13) Slide assembled puller flange and rods onto
output shaft. Then seat flange in notch of puller jaw
(Fig. 15).
(14) Position second puller jaw on gear and in
notch of puller flange (Fig. 16).(15) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place (Fig. 16).
(16) Install Puller and Bolt 6444 on puller rods.
Then secure puller to rods with retaining nuts (Fig.
17).
(17) Tighten puller bolt to remove gear from shaft
splines (Fig. 17).
Fig. 10 Fifth Gear Shift Fork Roll Pins
1 - FORK ROLL PINS
2 - FIFTH GEAR SHIFT FORK
Fig. 11 Countershaft Fifth Gear Clutch Gear Snap
Ring
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
Fig. 12 Countershaft Fifth Gear Needle Bearing
1 - FIFTH GEAR NEEDLE BEARING ASSEMBLY
2 - COUNTERSHAFT
Fig. 13 Countershaft Rear Bearing Thrust Washer
1 - THRUST WASHER (CONE SHAPED)
2 - THRUST WASHER PIN
21 - 50 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

Fig. 14 First Puller Jaw On Mainshaft Fifth
(Overdrive) Gear
1 - MAINSHAFT FIFTH GEAR
2 - JAWS 6459 OR HD JAWS 6820
3 - MAINSHAFT
Fig. 15 Seating Puller Flange In First Puller
1-JAWS
2 - PULLER FLANGE 6444-1
Fig. 16 Retaining Collar Over Puller Jaws
1-JAWS
2 - COLLAR 6444-8
Fig. 17 Fifth Gear From Mainshaft Splines
1 - COLLAR 6444-8
2 - JAWS 6459 OR 6820
3 - BOLT 6444
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE 6444-1
BR/BEMANUAL - NV4500 21 - 51
MANUAL - NV4500 (Continued)

(18) Remove bolts attaching mainshaft rear bear-
ing plate to gear case and remove fifth gear plate end
play shims and bearing cup (Fig. 18).
FRONT RETAINER
(1) Remove front retainer bolts (Fig. 19). Discard
retainer bolts. They should not be reused.
(2) Remove retainer by lightly tapping it back and
forth with plastic mallet. Then rock retainer back
and forth by hand to work it out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
(3) Remove seal from front retainer (Fig. 20). Col-
lapse one side of seal then pry it out with pry tool.(4) To remove front retainer bearing cup, assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
21).
(5) Insert Puller Jaws 6453-1 in puller flange (Fig.
21). Narrow lip of puller jaws will go under bearing
cup.
(6) Install Disc C-4487-1 into bearing retainer on
heavy duty transmissions for Insert 6453-2 to rest
upon.
Fig. 18 Mainshaft Fifth Gear Bearing Plate, Bearing
Shims, And Rear Bearing Cup
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 19 Front Bearing Retainer
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
Fig. 20 Bearing Retainer Seal
1 - SEAL
2 - FRONT BEARING RETAINER
Fig. 21 Puller Rods, Flange And Jaws
1 - RODS 6444-4
2 - FLANGE 6444-1
3 - JAWS 6453-1
21 - 52 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(7) Install assembled tools in front retainer (Fig.
22). Be sure puller jaws are seated under bearing
cup.
(8) Place Insert Tool 6453-2 in center of puller
jaws (Fig. 22). Insert tool is used to hold puller jaws
in place.
(9) Install Puller 6444 on puller rods (Fig. 23).
Then install retaining nuts on puller rods.
(10) Tighten puller bolt to draw bearing cup out of
retainer (Fig. 23).
DRIVE GEAR
(1) Remove drive gear (Fig. 24).
(2) Remove pilot bearing from drive gear (Fig. 25).
(3) To remove tapered bearing from drive gear,
assemble Puller Flange 6444-1 and Puller Rods
6444-6 (Fig. 26). Then position first Puller Jaw 6447
on bearing
(4) Slide assembled puller flange and rod tools
onto input shaft. Then seat flange in notch of puller
jaw.
(5) Position second Puller Jaw 6447 on gear and in
notch of puller flange.
(6) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place.
(7) Install Puller 6444 on puller rods then install
retaining nuts.
(8) Tighten puller bolt to remove bearing cone
from drive gear.
Fig. 22 Puller Tools In Front Retainer
1 - INSERT 6453-2
2 - FRONT RETAINER
3 - JAWS 6453-1
Fig. 23 Bearing Cup Puller
1 - WRENCH
2 - INSERT 6453-2
3 - FRONT RETAINER
4 - PULLER 6444
5 - WRENCH
Fig. 24 Drive Gear
1 - MAINSHAFT
2 - DRIVE GEAR
BR/BEMANUAL - NV4500 21 - 53
MANUAL - NV4500 (Continued)

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 27).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 28).
(4) Roll gear case onto left side (Fig. 29).
(5) To remove mainshaft assembly (Fig. 29) lift
front end of mainshaft slightly.
NOTE: Handling mainshaft carfully because gears
are lose on the mainshaft.
(6) Grasp mainshaft rear splines, then turn spline
end of mainshaft counterclockwise to rotate shaft and
geartrain out of case. Tilt mainshaft outward and
removed from case.
Fig. 25 Pilot Bearing
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 26 Front Bearing Puller
1 - PULLER 6444
2 - RODS 6444-6
3 - JAWS 6447
4 - COLLAR 6444-8
5 - FLANGE 6444-1
6 - DRIVE GEAR
Fig. 27 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 28 Fourth Gear Clutch Gear Stop Ring
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
21 - 54 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
30).
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 31).
(3) Remove reverse idler shaft (Fig. 32).(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 33).
(5) Remove idler gear (Fig. 34).
Fig. 29 Mainshaft And Geartrain
1 - MAINSHAFT AND CASE
Fig. 30 Countershaft Rear Bearing Plate
1 - REAR BEARING PLATE
2 - COUNTERSHAFT
Fig. 31 Countershaft End Play Shim And Rear
Bearing Cup
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
Fig. 32 Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
BR/BEMANUAL - NV4500 21 - 55
MANUAL - NV4500 (Continued)