DODGE RAM 2001 Service Repair Manual

(9) Press the 5-6 synchro assembly from the out-
put shaft.
(10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 43).
COUNTERSHAFT
(1) Install the countershaft into Fixture 8227 with
press blocks located under the fifth countershaft
gear.
(2) Place the assembly into a shop press.
(3) Use Guide 8235 on end of countershaft and
press the countershaft fifth gear from the counter-
shaft (Fig. 44).
(4) Place countershaft in Fixture 8227 with press
blocks placed under the sixth countershaft gear.
(5) Use Guide 8235 on end of countershaft and
press the countershaft sixth gear from the counter-
shaft (Fig. 45).
(6) Remove countershaft from the press and Fix-
ture 8227.
Fig. 41 FIRST GEAR BLOCKER RINGS
1 - OUTPUT SHAFT
2 - FIRST GEAR BLOCKER RINGS
3 - FIRST GEAR FRICTION CONE
Fig. 42 SECOND GEAR 1-2 SYNCRO
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING SLEEVE
3 - SECOND GEAR
4 - FIXTURE
5 - 1-2 SYNCHRO 8227
Fig. 43 SIXTH GEAR COMPONENTS
1 - SIXTH GEAR FRICTION CONE
2 - SIXTH GEAR
3 - OUTPUT SHAFT
4 - SIXTH GEAR BLOCKER RING
5 - 5-6 SYNCHRO
21 - 106 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(7) Remove fourth countershaft gear, friction cone,
blocker ring and bearing from the countershaft (Fig.
46).
(8) Install countershaft into Fixture 8227 with
press blocks located under the third countershaft
gear
(9) Place assembly into a shop press and press
third countershaft gear, 3-4 synchro, and fourth
countershaft gear bearing sleeve from the counter-
shaft (Fig. 47).
(10) Remove countershaft from the press and Fix-
ture 8227.
(11) Remove third countershaft gear bearing from
the countershaft (Fig. 48).
(12) The 2-3 thrust washer should not normally
need to be removed from the countershaft. If neces-
sary slid 2-3 thrust washer off countershaft.
Fig. 44 FIFTH COUNTERSHAFT GEAR
1 - GUIDE 8235
2 - FIFTH COUNTER SHAFT GEAR
3 - FIXTURE 8227
Fig. 45 SIXTH COUNTERSHAFT GEAR
1 - GUIDE 8235
2 - SIXTH COUNTER SHAFT GEAR
3 - FIXTURE 8227
Fig. 46 FOURTH COUNTERSHAFT GEAR
1 - FOURTH GEAR BLOCKER RING
2 - FOURTH GEAR BEARING
3 - COUNTERSHAFT
4 - FOURTH GEAR FRICTION CONE
5 - FOURTH COUNTERSHAFT GEAR
BR/BEMANUAL - NV5600 21 - 107
MANUAL - NV5600 (Continued)

CLUTCH HOUSING
(1) Remove input shaft retainer bolts from the
clutch housing and remove retainer (Fig. 49).
(2) Remove countershaft oil guide from the coun-
tershaft front bearing bore in the clutch housing (Fig.
50).
(3) Remove countershaft front bearing race, end-
play shims, and spacer from the clutch housing with
Remover 6061-1 and Handle C-4171 (Fig. 51).
(4) Remove input shaft bearing race with Remover/
Installer 8237 and Handle C-4171.
(5) Remove input shaft oil guide and retainer seal
(Fig. 52).
Fig. 47 THIRD COUNTERSHAFT GEAR
1 - THIRD COUNTERSHAFT GEAR
2 - FIXTURE 8227
3 - 3-4 SYNCHRO
4 - BEARING SLEEVE
5 - COUNTERSHAFT
Fig. 48 THIRD GEAR BEARING
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR BEARING
Fig. 49 INPUT SHAFT RETAINER
1 - INPUT SHAFT RETAINER
2 - CLUTCH HOUSING
21 - 108 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

CLEANING - TRANSMISSION
Clean the gears, bearings shafts, extension/adapter
housing and gear case with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Run a tap through the gear case bolt holes if the
threads need minor cleanup. Helicoil inserts can be
used to repair seriously damaged threaded holes if
necessary.
INSPECTION - TRANSMISSION
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped or
worn. Replace the gear if the teeth are chipped,
cracked or worn thin.
Inspect the drive gear and bearings. Minor
scratches and burrs on the gear surfaces can be
reduced with an oil stone and 400 grit paper wetted
with oil. Replace either bearing if worn, or damaged.
Replace the gear if any teeth, splines, or bearing sur-
faces are also worn or damaged.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Minor corrosion, nicks, or pit-
ting can be smoothed with 400 grit emery and pol-
ished out with crocus cloth. Wet the abrasive paper
Fig. 50 COUNTERSHAFT OIL GUIDE
1 - CLUTCH HOUSING
2 - COUNTERSHAFT OIL GUIDE
Fig. 51 FRONT COUNTERSHAFT BEARING
1 - CLUTCH HOUSING
2 - HANDLE C-4171
3 - REMOVER 6061-1
Fig. 52 OIL GUIDE AND SEAL
1 - INPUT SHAFT OIL GUIDE
2 - INPUT SHAFT OIL SEAL
BR/BEMANUAL - NV5600 21 - 109
MANUAL - NV5600 (Continued)

and crocus cloth with oil when smoothing/polishing.
Replace the retainer if worn or damaged in any way.
Do not reuse original retainer bolts. Install new bolts
during assembly.
Inspect the countershaft and bearings. Replace the
bearings if worn, rough, flat spotted or heat checked.
Check the countershaft gear teeth carefully. Small
nicks, scratches or burrs can be removed with an oil
stone and 400 grit paper wetted with oil. Replace the
shaft if any of the teeth are worn, cracked, broken or
severely chipped.
Be sure to check condition of the countershaft bear-
ing cups. Replace either bearings cup if worn, or
damaged.
Check condition of the mainshaft. Inspect all the
bearing surfaces, splines and threads. Also check con-
dition of the snap ring grooves in the hub area and
the speedometer drive gear teeth. Minor scratches or
burrs can be removed with an oil stone and polished
with crocus cloth. However, replace the shaft if any
surfaces exhibit considerable wear or damage.
Check condition of the gear case and extension or
adapter housing. Be sure the alignment dowels in the
case top surface and in the housing/adapter are tight
and in good condition.
Run a tap through the gear case bolt holes if the
threads need minor cleanup. Helicoil inserts can be
used to repair seriously damaged threaded holes if
necessary.
Be sure all case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. This is
especially important as gaskets are not used in the
transmission. Minor nicks and scratches on the seal-
ing surfaces can be dressed off with a fine tooth file
or oil stone.
Replace the gear case or housing/adapter if cracked
or broken. Do not attempt to repair this type of dam-
age by welding or brazing.
Check condition of the countershaft fifth gear com-
ponents. This includes the shift lug and rail located
in the gear case and the rail bushings.
Inspect the gear and hub assembly. Minor burrs
can be cleaned up with an oil stone. However, the
gear and hub assembly should be replaced if the
teeth or splines are excessively worn, or damaged.
The synchro sleeve should also be replaced if worn or
damaged in any way. Do not reuse synchro struts
that are worn or springs that are collapsed or
severely distorted. Replace worn distorted synchro
parts to avoid shift problems after assembly and
installation.
The shift fork should be inspected for evidence of
wear and distortion. Check fit of the sleeve in the
fork to be sure the two parts fit and work smoothly.
Replace the fork if the roll pin holes are worn over-
size or damaged. Do not attempt to salvage a wornfork. It will cause shift problems later on. Replace
shift fork roll pins if necessary or if doubt exists
about their condition.
The bearings should be examined carefully for
wear, roughness, flat spots, pitting or other damage.
Replace the bearings if necessary.
Inspect the blocker ring and clutch gear. replace
either part if worn or damaged in any way. Also be
sure replacement parts fit properly before proceeding
with assembly.
Examine the 1-2 synchro hub and sleeve for wear
or damage. Replace sleeve and hub if the splines are
worn, chipped or damaged.
Replace the synchro struts if worn, or chipped. Also
replace the springs if collapsed, distorted or broken.
Inspect the mainshaft geartrain components.
Check teeth on all gears, hubs, clutch gears, stop
rings and clutch rings. The teeth must be in good
condition and not worn, cracked or chipped. Replace
any component that exhibits wear or damage.
Examine the synchro stop rings, clutch rings and
clutch gears. Replace any part that exhibits wear,
distortion or damage. Replace the clutch rings if the
friction material is burned, flaking off or worn.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the wash-
ers if worn or the locating pin notches are distorted.
Check condition of the synchro struts and springs.
Replace these parts if worn, cracked or distorted.
ASSEMBLY
NOTE: Gaskets are not used in the transmission.
Use MoparTGasket Maker or equivalent on all gear
case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Place second gear on bench with the synchro
clutch ring up.
(2) Install second gear synchro inner blocker ring
onto second gear (Fig. 53).
(3) Install second gear synchro friction cone over
the blocker ring and onto second gear (Fig. 54).
(4) Install second gear synchro outer blocker ring
over the second gear synchro friction cone. Align one
of the lugs on the outer ring with a lug on the inner
ring (Fig. 55).
(5) Install 1-2 synchro assembly onto the second
gear assembly (Fig. 56).
(6) Reverse assembly on the bench.
21 - 110 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

Fig. 53 Inner Blocker Ring
1 - INNER BLOCKER RING
2 - GEAR
Fig. 54 Friction Cone
1 - LOW AREA
2 - GEAR
3 - HIGH AREA
Fig. 55 Outer Blocker Ring
1 - OUTER BLOCKER RING
2 - LUG
3 - GEAR
Fig. 56 3-4 Synchro Assembly
1 - SYNCHRO
2 - GEAR
BR/BEMANUAL - NV5600 21 - 111
MANUAL - NV5600 (Continued)

(7) Install second gear bearing into second gear
(Fig. 57).
(8) Place completed 1-2 synchro, second gear and
second gear bearing to a shop press with second gear
facing upward.
(9) Install output shaft into the second gear 1-2
synchro assembly with the front of the output shaft
facing upward (Fig. 58).
(10) Press the output shaft into position.(11) Place first gear on bench with the synchro
clutch ring up.
(12) Install first gear synchro inner blocker ring
onto first gear (Fig. 53).
(13) Install first gear synchro friction cone over the
blocker ring and onto first gear (Fig. 54).
(14) Install first gear synchro outer blocker ring
over the first gear synchro friction cone. Align one of
the lugs on the outer ring with a lug on the inner
ring (Fig. 55).
(15) Reverse the output shaft in the press.
(16) Install first gear bearing sleeve onto the out-
put shaft.
(17) Install first gear bearing sleeve the remainder
of the way onto the output shaft using Installer 8228
and a shop press (Fig. 59).
(18) Install first gear and blocker assembly onto
the output shaft (Fig. 60).
(19) Install first gear bearing over the output shaft
and into first gear.
(20) Install output shaft thrust washer onto the
output shaft (Fig. 61).
Fig. 57 Second Gear Bearing
1 - BEARING
2 - GEAR
Fig. 58 Output Shaft Into 1-2 Synchro
1 - OUTPUT SHAFT
2 - 1-2 SYNCHRO
3 - SECOND GEAR
Fig. 59 First Gear Bearing Sleeve
1 - INSTALLER 8228
2 - FIRST GEAR BEARING SLEEVE
21 - 112 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(21) Install rear output shaft bearing onto the out-
put shaft with Installer 8228 and a shop press (Fig.
62).
(22) Install anewsnap-ring to hold the rear out-
put bearing onto the output shaft. Select and install
the thickest snap-ring which will fit into the groove.
(23) Reverse output shaft in the Fixture 8227 and
support the shaft with press blocks under first gear.
(24) Install sixth gear bearing onto the output
shaft.
(25) Install sixth gear onto the output shaft and
over the sixth gear bearing (Fig. 63).
(26) Install the sixth gear friction cone onto sixth
gear.
(27) Install sixth gear blocker ring over the sixth
gear friction cone (Fig. 64).
(28) Install Guide 8235 onto the end of the output
shaft (Fig. 65).
(29) Install 5-6 synchro over Guide 8235 and onto
the output shaft (Fig. 66).
(30) Press 5-6 synchro onto the output shaft with
Installer 8156 and a shop press.
(31) Install output shaft pocket bearing onto the
output shaft.
Fig. 60 First Gear And Blocker Assembly
1 - OUTPUT SHAFT
2 - 1ST GEAR AND BLOCKER ASSEMBLY
Fig. 61 Output Shaft Thrust Washer
1 - OUTPUT SHAFT
2 - OUTPUT SHAFT THRUST WASHER
Fig. 62 Rear Output Shaft Bearing
1 - INSTALLER 8228
2 - REAR OUTPUT SHAFT BEARING
BR/BEMANUAL - NV5600 21 - 113
MANUAL - NV5600 (Continued)

Fig. 63 Sixth Gear
1 - 6TH GEAR
2 - 6TH GEAR BEARING
Fig. 64 Sixth Gear Blocker Ring
1 - 6TH GEAR BLOCKER RING
2 - 6TH GEAR FRICTION CONE
Fig. 65 Output Shaft Guide
1 - GUIDE 8235
2 - OUTPUT SHAFT
Fig. 66 5-6 Synchro
1 - INSTALLER 8156
2 - 5-6 SYNCHRO
21 - 114 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(32) Press pocket bearing the remainder of the
way onto the output shaft using Guide 8235 and a
shop press (Fig. 67).
(33) Install anewsnap-ring to hold the output
shaft pocket bearing onto the output shaft.
COUNTERSHAFT
(1) Place third countershaft gear on the bench
with the synchro clutch ring up.
(2) Install third countershaft gear friction cone
onto third gear (Fig. 68).
(3) Install third countershaft gear blocker ring
onto the friction cone (Fig. 69).
(4) Install 3-4 synchro assembly onto the blocker
ring/gear assembly (Fig. 70).
(5) Reverse the assembly on the bench.
(6) Install third countershaft gear bearing into the
third countershaft gear.
(7) Install 2-3 thrust washer onto the countershaft.
(8) Place third gear/3-4 synchro assembly in a shop
press.
(9) Install countershaft through the third gear/3-4
synchro assembly.
(10) Press countershaft into the 3-4 synchro
assembly (Fig. 71).
(11) Install fourth countershaft gear bearing sleeve
onto the output shaft.
(12) Press fourth countershaft bearing sleeve onto
the countershaft with Installer 8228 and a shop
press.(13) Place fourth countershaft gear on the bench
with the synchro clutch ring up.
(14) Install fourth countershaft gear friction cone
onto fourth countershaft gear (Fig. 68).
(15) Install fourth countershaft gear blocker ring
onto the friction cone (Fig. 69).
(16) Install fourth countershaft gear bearing into
the fourth countershaft gear.
(17) Place sixth countershaft gear in the shop
press.
(18) Position fourth countershaft gear assembly
onto the sixth countershaft gear (Fig. 72).
(19) Install countershaft into the fourth/sixth coun-
tershaft gear assembly in the shop press.
Fig. 67 Output Shaft Pocket Bearing
1 - GUIDE 8235
2 - POCKET BEARING
Fig. 68 Friction Cone Onto Gear
1 - FRICTION CONE
2 - GEAR
3 - CLUTCH RING
Fig. 69 Blocker Ring Onto Friction Cone
1 - BLOCKER RING
2 - GEAR
3 - FRICTION CONE
BR/BEMANUAL - NV5600 21 - 115
MANUAL - NV5600 (Continued)