tow DODGE RAM 2001 Service Repair Manual

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.
(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: The use of Fixture 8241 for moving and han-
dling the NV5600 is required. The fixture supports
the transmission at the center of gravity in order to
ease mounting the transmission into the build fix-
ture.
(1) Using Fixture 8241, mount the transmission
into the Build Fixture 8230 (Fig. 5).
(2) Rotate the transmission to the horizontal posi-
tion, if necessary.
(3) Remove the shift tower (Fig. 6) and isolator
plate (Fig. 7).
(4) Remove primary shift rail detent plug (Fig. 8).
(5) Remove primary shift rail detent spring (Fig.
9).
(6) Remove primary shift rail detent plunger (Fig.
10).
(7) Remove clutch housing bolts (10) (Fig. 11) from
inside the housing.
(8) Remove shift rail blocker bolt (Fig. 12) from the
side of the transmission gear case.
Fig. 5 TRANSMISSION BUILD FIXTURE
1 - FIXTURE
2 - TRANSMISSION
Fig. 6 Shift Tower
1 - SHIFT TOWER
2 - TRANSMISSION
BR/BEMANUAL - NV5600 21 - 95
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)

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. 94).(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.
(10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 95).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.
(12) The difference between the two measurements
is the end-play for the reverse countershaft gear
assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.006-
0.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
(14) Use Installer to install the reverse counter-
shaft bearing race into the extension/adapter hous-
ing.
(15) Install back-up lamp switch and a new gasket
into the extension/adapter housing. Tighten switch to
28 N´m (20 ft.lbs.).
(16) Install crossover cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 96).
Fig. 94 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR 6311
Fig. 95 Reverse Countershaft Gear Bearing Race
Bore
1 - GAUGE BAR 6311 TO BEARING RACE BORE
MEASUREMENT
21 - 124 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(18) Install crossover detent plunger, spring and
plug into the extension/adapter housing. Tighten the
plug to 47.5 N´m (35 ft.lbs.) (Fig. 97).
(19) Apply sealer to the surface of the transmis-
sion case.
(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter
housing onto the transmission gear case. Tighten
bolts to 48 N´m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N´m (41 ft.lbs.).
(23) Install primary shift rail detent plunger,
spring and plug into the transmission case. Tighten
detent plug to 47.5 N´m (35 ft.lbs.).(24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If a new transmission is being installed, be
sure to 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.
NOTE: Use a heavy duty scissors style transmis-
sion jack to install the transmission.
Before installation apply light coat of Mopar high
temperature bearing grease to contact surfaces of fol-
lowing components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(1) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(2) Mount transmission on jack and position trans-
mission under vehicle.
(3) Raise transmission until input shaft is centered
in clutch disc hub.
(4) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(5) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(6) Install and tighten transmission-to-engine
block bolts.
(7) Install clutch slave cylinder.
(8) Connect backup light switch wires.
(9) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(10) Position transmission harness wires in clips
on transmission.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
Fig. 96 Crossover Cam
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
Fig. 97 Crossover Cam Detent Plug
1 - DETENT PLUG
2 - EXTENSION HOUSING
BR/BEMANUAL - NV5600 21 - 125
MANUAL - NV5600 (Continued)

(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify that the shift tower, isolator plate and
the shift socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso-
lator plate and the transmission case. Tighten bolts
to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
(3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts
to 41-47 N´m (30-35 ft. lbs.) if case has 3/8 studs. If
case has 5/16 studs tighten to 30-41 N´m (22-30 ft.
lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.(6) Install propeller shafts with reference marks
aligned.
(7) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(8) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(9) Install exhaust system components.
(10) Remove support and lower vehicle.
(11) Shift transmission into third gear.
(12) Clean the mating surfaces of shift tower, iso-
lator plate, and transmission case with suitable wax
and grease remover.
(13) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission case. Do not
over apply sealant.
(14) Install isolator plate onto the transmission
case, metal side down.
(15) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(16) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(17) Install the bolts to hold the shift tower to the
isolator plate and the transmission case. Tighten the
shift tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(18) Install shift lever boot and bezel.
(19) Connect battery negative cable.
SPECIFICATIONS
SPECIFICATIONS - NV5600
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Crossover Cam and
Detent48 35 -
Bolt, Input Retainer 28 20 -
Bolt, 5-6 Crossover Bracket 28 20 -
Bolt, Clutch Housing 48 35 -
Bolt, Extension/Adapter Housing 48 35 -
Bolt, Shift Tower 9 7 80
Switch, Back-up Lamp 28 20 -
Bolt, Shift Blocker 55 41 -
Bolt, PTO Cover 40 30 -
Pivot, Clutch Release Lever 22 16 -
Plug, Fill 30 22 -
Nut, Output Shaft 339 250 -
21 - 126 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the propeller shaft.
(2) Remove the transfer case.
(3) Remove adapter housing seal with a pry tool or
a slide hammer mounted screw.
INSTALLATION
(1) Install extension housing seal with Installer
8154 and Handle C-4171.
(2) Install propeller shaft with reference marks
aligned.
EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Mark propeller shaft and pinion yoke for
installation reference and remove the propeller shaft.
(3) Remove the extension housing seal with a suit-
able pry tool or a slide hammer mounted screw.
(4) Remove the extension housing bushing with
Remover 8155 (Fig. 98).
INSTALLATION
(1) Install extension housing bushing with
Installer 8156 (Fig. 99) and Handle C-4171.
(2) Install adapter housing seal with Installer
8154 and Handle C-4171 (Fig. 100).
(3) Install transfer case and propeller shaft(s).
(4) Check and fill transmission.
(5) Remove support and lower vehicle.
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 gear case.
(5) Remove the shift tower (Fig. 101) and isolator
plate (Fig. 102) from the transmission.
Fig. 99 Extension Housing Bushing Installer
1 - HANDLE
2 - INSTALLER
3 - BUSHING
Fig. 100 Extension Housing Seal Installer
1 - INSTALLER
2 - HANDLE
Fig. 98 Extension Housing
1 - REMOVER
21 - 132 MANUAL - NV5600BR/BE

INSTALLATION
(1) Shift transmission into third gear.
(2) Clean the mating surfaces of shift tower, isola-
tor plate, and transmission gear case with suitable
wax and grease remover.
(3) Apply MopartGasket Maker, or equivalent, to
the sealing surface of the transmission. Do not over
apply sealant.
(4) Install the isolator plate onto the transmission,
metal side down.
(5) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
top of the isolator plate.
(6) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
(7) Install the bolts to hold the shift tower to the
isolator plate and the transmission gear case.
Tighten the shift tower bolts to 8±10 N´m (7±9 ft.
lbs.).
(8) Install the shift lever extension, shift boot, and
bezel.
Fig. 101 Remove Shift Tower
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 102 Remove Shift Tower Isolator Plate
1 - ISOLATOR PLATE
2 - TRANSMISSION
BR/BEMANUAL - NV5600 21 - 133
SHIFT COVER (Continued)

(33) Compress front servo rod guide about 1/8 inch
with Valve Spring Compressor C-3422-B (Fig. 32).
(34) Remove front servo rod guide snap-ring. Exer-
cise caution when removing snap-ring. Servo bore
can be scratched or nicked if care is not exercised.
(35) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
(36) Compress rear servo spring retainer about
1/16 inch with Valve Spring Compressor C-3422-B
(Fig. 33).
(37) Remove rear servo spring retainer snap-ring.
Then remove compressor tools and remove rear servo
spring and piston.
(38) Inspect transmission components.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
CLEANING
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components andcirculate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
Lubricate transmission parts with MopartATF +4,
type 9602, transmission fluid during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-GlydeŸ to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bush-
ings contribute to low pressures, clutch slip and
accelerated wear of other components. However, do
not replace bushings as a matter of course. Replace
bushings only when they are actually worn, or
scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
Fig. 32 Compressing Front Servo Rod Guide
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
Fig. 33 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 165
AUTOMATIC TRANSMISSION - 42RE (Continued)

seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.
Pre-sized service bushings are available for
replacement purposes. Only the sun gear bushings
are not serviced.
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
ASSEMBLY
Do not allow dirt, grease, or foreign material to
enter the case or transmission components during
assembly. Keep the transmission case and compo-
nents clean. Also make sure the tools and workbench
area used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made fromlint freematerial. Lint will stick
to transmission parts and could interfere with valve
operation, or even restrict fluid passages.
Lubricate the transmission components with
Moparttransmission fluid during reassembly. Use
MopartDoor Ease, or Ru-GlydeŸ on seals and
O-rings to ease installation.
Petroleum jelly can also be used to hold thrust
washers, thrust plates and gaskets in position during
assembly. However,do notuse chassis grease, bear-
ing grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and inter-
fere with valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and subassemblies are easily installed by
hand when properly aligned.
If a part seems extremely difficult to install, it is
either misaligned or incorrectly assembled. Also ver-
ify that thrust washers, thrust plates and seal rings
are correctly positioned before assembly. These parts
can interfere with proper assembly if mis-positioned.
The planetary geartrain, front/rear clutch assem-
blies and oil pump are all much easier to install
when the transmission case is upright.
(1) Install rear servo piston, spring and retainer
(Fig. 34). Install spring on top of servo piston and
install retainer on top of spring.(2) Install front servo piston assembly, servo
spring and rod guide (Fig. 35).
(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap-ring (Fig. 36).
Fig. 34 Rear Servo Components
1 - SERVO PISTON
2 - PISTON SPRING
3 - SNAP-RING
4 - RETAINER
5 - PISTON SEAL
Fig. 35 Front Servo Components
1 - PISTON SEAL RINGS
2 - SERVO PISTON
3 - SNAP-RING
4 - ROD GUIDE
5 - SPRING
6 - ROD
21 - 166 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

(11) Check seal ring on rear clutch retainer hub
and seal rings on input shaft (Fig. 43). Also verify
that shaft seal rings are installed in sequence shown.
(12) Install rear clutch thrust washer (Fig. 44).
Use additional petroleum jelly to hold washer in
place if necessary.
(13) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 45). Rotate front
clutch retainer back and forth until completely
seated on rear clutch retainer.
(14) Coat intermediate shaft thrust washer with
petroleum jelly. Then install washer in rear clutch
hub (Fig. 46). Use enough petroleum jelly to holdwasher in place. Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also note
that washer only fits one way in clutch hub. Note
thickness of this washer. It is a select fit part and is
used to control transmission end play.
Fig. 43 Input Shaft Seal Ring Location
1 - INPUT SHAFT
2 - TEFLON SEAL RING
3 - PLASTIC SEAL RING
4 - REAR CLUTCH RETAINER
Fig. 44 Installing Rear Clutch Thrust Washer
1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER (FIBER)
Fig. 45 Assembling Front And Rear Clutch Units
1 - TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 - REAR CLUTCH ASSEMBLY
Fig. 46 Installing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 169
AUTOMATIC TRANSMISSION - 42RE (Continued)