transmission DODGE RAM 2001 Service Repair Manual

DISASSEMBLY
FRONT HOUSING
(1) Shift transmission into Neutral.
(2) If lubricant was not drained out of transmis-
sion during removal, remove drain plug and drain
lubricant.
(3) Inspect drain plug magnet for debris.
(4) Remove backup light switch located on passen-
ger side of rear housing (Fig. 3).
(5) Remove shift tower bolts and remove tower and
lever assembly (Fig. 4).(6) Remove shift shaft lock bolt (Fig. 5). Bolt is
located at top of front housing just forward of shift
tower. Bolt is a shoulder bolt that secures the shift
shaft bushing and lever.
(7) Remove bolts attaching input shaft bearing
retainer to front housing and remove retainer.
NOTE: Use pry tool to carefully lift retainer and
break sealer bead (Fig. 6).
(8) Remove bearing retainer from input shaft (Fig.
7).
(9) Remove snap ring that secures input shaft in
front bearing (Fig. 8).
Fig. 3 Backup Light Switch
1 - BACKUP LIGHT SWITCH
Fig. 4 Shift Tower
1 - SHIFT TOWER AND LEVER ASSEMBLY
2 - SHIFT SOCKET
3 - SEAL
Fig. 5 Shift Shaft Lock Bolt
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 6 Loosening Bearing
1-PRYTOOL
2 - INPUT SHAFT BEARING RETAINER
BR/BEMANUAL - NV3500 21 - 5
MANUAL - NV3500 (Continued)

(13) Remove rear bolt holding reverse idler shaft
in housing.
REAR HOUSING - 2WD
(1) On 2-wheel drive transmission, remove three
bolts that attach output shaft bearing retainer to
rear case (Fig. 22). Bolts are rear of shift tower open-
ing.
Fig. 19 Reverse Idler Shaft/Support
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 20 Fixture Assembly
1 - FIXTURE 6747
2 - ADAPTER 6747-1A
3 - CUP 8115
4 - REVERSE IDLER PEDESTAL
5 - ADAPTER 6747-2B
Fig. 21 Geartrain And Housing Mounted On Fixture
1 - INPUT SHAFT
2 - COUNTERSHAFT
3 - FIXTURE 6747
Fig. 22 Output Shaft
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
BR/BEMANUAL - NV3500 21 - 9
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)

(8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 78).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 78). Verify snap
ring is seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/
BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
(2) If necessary, the shift shaft bushing can be
replaced as follows:
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.
(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.
(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case.(3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case.
(4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive
the detent bushings through the outer case and
into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
the case.
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
GEARTRAIN ASSEMBLY
(1) Install Adapter 6747-1A on input shaft hub of
Fixture 6747 (Fig. 79). Then install Adapter 6747-2B
on front bearing hub of countershaft. Be sure the
shoulder is seated against the countershaft.
(2) Install input shaft in fixture tool. Make sure
Adapter Tool 6747-1A is positioned under shaft as
shown (Fig. 80).
(3) Install pilot bearing in input shaft (Fig. 80).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
Fig. 78 Idler Gear And Shaft Assembly
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
BR/BEMANUAL - NV3500 21 - 27
MANUAL - NV3500 (Continued)

(11) On 2-wheel drive transmission, thread one
Alignment Pin 8120 in center or passenger side hole
of output shaft bearing retainer. Then position
retainer on fifth gear as shown (Fig. 86).(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
87). Arm of fifth-reverse fork goes through slot in 1-2
fork.
(13) Install assembled shift forks in synchro
sleeves and verify forks are seated in sleeves (Fig.
88).
Fig. 85 Reverse Idler Assembly On Assembly
Fixture Tool
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - TOOL PEDESTAL
Fig. 86 Positioning Output Shaft Bearing Retainer
1 - PIN 8120
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 87 1-2 And Fifth-Reverse Shift Forks
1 - INSERT ARM THROUGH 1-2 FORK
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
Fig. 88 Shift Forks In Synchro
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
21 - 30 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(3) Apply Mopar Gasket Maker or equivalent to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 93).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 91).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 91).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 91).
(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 96).
(10) Lubricate lip of new rear seal (Fig. 97) with
MopartDoor Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 97).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify that all synchro sleeves are in Neutral
position (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position for reassembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
Fig. 95 Adapter Housing - 4WD
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
Fig. 96 Rear Bearing Snap Ring - 4WD
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 97 Rear Seal
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
BR/BEMANUAL - NV3500 21 - 33
MANUAL - NV3500 (Continued)

(2) Install 3-4 shift fork in synchro sleeve (Fig. 98).
Verify groove in fork arm is aligned with grooves in
1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
99)with shaft detent notches to the rear.
(4) Assemble shift shaft shift lever and bushing
(Fig. 100). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 101).(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
102).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 103).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
Fig. 98 3-4 Shift Fork
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 99 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 100 Shift Shaft Lever And Bushing
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 101 Install Shift Shaft Lever And Bushing
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
21 - 34 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(5) Apply 1/8 in. wide bead of MopartGasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 111).
(6) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(9) Place transmission in horizontal position.
(10) Apply MopartGasket Maker or equivalent, to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 112).
(11) Install and start housing attaching bolts by
hand (Fig. 112). Then tighten bolts to 34 N´m (25 ft.
lbs.).
(12) Install shift shaft bushing lock bolt (Fig. 113).
Apply Mopar Gasket Maker or equivalent to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubricate then install shift shaft detent
plunger in housing bore (Fig. 114). Lubricate plunger
with petroleum jelly or gear lubricant. Verify plunger
is fully seated in detent notch in shift shaft.
(14) Install detent spring inside plunger (Fig. 114).
(15) Install detent plug in end of Installer 8123.
Position plug on detent spring and compress spring
until detent plug pilots in detent plunger bore. Drive
detent plug into transmission case until plug seats.
(16) Install backup light switch (Fig. 115).
Fig. 110 Countershaft Front Bearing
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 111 Seal Front/Rear Housings
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 112 Housing Bolts
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
BR/BEMANUAL - NV3500 21 - 37
MANUAL - NV3500 (Continued)

(17) Install input shaft snap ring (Fig. 116).
(18) Installnewoil seal in front bearing retainer
with Installer 6448 (Fig. 117).
(19) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
118).
(20) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
119). Verify bolt holes are aligned before seating
retainer.
CAUTION: Be sure sealer does not get into the oil
feed hole in the transmission case or bearing
retainer.
Fig. 113 Shift Shaft Bushing Lock Bolt
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 114 Shift Shaft Detent Plunger
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
Fig. 115 Backup Light Switch
1 - BACKUP LIGHT SWITCH
Fig. 116 Shaft Snap Ring - Typical
1 - INPUT SHAFT SNAP RING
Fig. 117 Oil Seal In Front Bearing Retainer
1 - INSTALLER 6448
2 - FRONT BEARING RETAINER
21 - 38 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(21) Install and tighten bearing retainer bolts to
7-10 N´m (5-7 ft. lbs.) (Fig. 120).
SHIFT TOWER AND LEVER
(1) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(2) Shift the transmission into third gear.
(3) Align and install shift tower and lever assem-
bly (Fig. 121). Be sure shift ball is seated in socket
and the offset in the tower is toward the passenger
side of the vehicle before installing tower bolts.
(4) Install shift tower bolts (Fig. 122) and tighten
bolts to 8.5 N´m (75.2 in. lbs.).
Fig. 118 Seal Bearing Retainer And Housing -
Typical
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
Fig. 119 Input Shaft Bearing Retainer
1 - INPUT SHAFT
2 - OIL FEED
3 - BEARING RETAINER
Fig. 120 Input Shaft Bearing Retainer Bolts - Typical
1 - RETAINER BOLTS
Fig. 121 Shift Tower
1 - SHIFT TOWER
BR/BEMANUAL - NV3500 21 - 39
MANUAL - NV3500 (Continued)