NV5600 DODGE RAM 2001 Service Owner's Guide

CLUTCH HOUSING
(1) Install input shaft bearing race so that the
bearing race protrudes 0.3 in. above the front surface
of the clutch housing. Install bearing race with
Remover/Installer 8237 and Handle C-4171.
(2) Install countershaft front bearing race into the
clutch housing so that the bearing race protrudes 0.4
in. above the front surface of the clutch housing.
Install bearing race with Remover 6061-1 and Han-
dle C-4171.
(3) Install countershaft oil guide and spacer into
the countershaft front bearing bore in the clutch
housing (Fig. 78).
(4) Clean all old sealer from the input shaft
retainer and the clutch housing butDO NOTapply
new sealer at this time. New sealer will be applied
after all the preload measurements are made and
end-play shims are installed.
NOTE: Do not replace the input shaft seal at this
time. A new seal will be installed after all the pre-
load measurements are made and endplay shims
are installed.(5) Install input shaft retainer onto the clutch
housing and install bolts to hold the input shaft
retainer.
Fig. 76 Input Shaft Oil Guide
1 - INPUT SHAFT
2 - INPUT SHAFT OIL GUIDE
Fig. 77 Output Shaft Pocket Bearing Race
1 - HANDLE C-4171
2 - INPUT SHAFT
3 - INSTALLER C-4628
Fig. 78 Oil Guide and Spacer
1 - 0.3 IN BEYOND FLUSH
2 - 0.4 IN BEYOND FLUSH
21 - 118 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

GEARTRAIN
(1) Install input shaft into Support Stand 8246.
(2) Install fifth gear friction cone onto the input
shaft.
(3) Install fifth gear blocker ring onto the fifth
gear friction cone.
(4) Install output shaft into the input shaft (Fig.
79).
(5) Install countershaft into the Support Stand
8246 and verify that all gears are meshed with their
mates on the mainshaft (Fig. 80).
(6) Install Fixture 8232 to the output shaft and
the countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5±6 synchro
together during the remainder of the installation pro-
cedure.(8) Attach and engine crane or equivalent to Fix-
ture 8232 and move the geartrain from the Support
Stand 8246 to the clutch housing (Fig. 81).
(9) Install shift forks and rails onto the geartrain
(Fig. 82).
NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) Install geartrain and shift rails into the clutch
housing. Lower the geartrain and rails into the hous-
ing slowly while guiding input shaft through input
shaft seal. Avoid any binds on the shift rails, forks
and synchros as the rails enter their bushings.
CAUTION: Do not damage input shaft seal with the
input shaft splines.
Fig. 79 Install Output Shaft to Input Shaft
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND 8246
Fig. 80 Countershaft to Mainshaft
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND 8246
BR/BEMANUAL - NV5600 21 - 119
MANUAL - NV5600 (Continued)

(11) With the geartrain approximately 1/4 in. from
the clutch housing, remove Holding Tool 8242 from
the 5-6 synchro (Fig. 83).
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts (Fig.
84).
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
Fig. 81 Lift Geartrain with Engine Crane
1 - FIXTURE 8232
2 - SUPPORT STAND 8246
Fig. 82 Install Shift Rails
1 - SHIFT RAILS
Fig. 83 Holding Tool 8242
1 - HOLDING TOOL 8242
2 - 5-6 SYNCHRO
Fig. 84 5-6 Crossover Bracket Bolts
1 - 5-6 CROSSOVER BRACKET
21 - 120 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

TRANSMISSION GEAR CASE
(1) Install rear output shaft bearing race into the
transmission gear case with Installer C-4308 and
Handle C-4171.
(2) Install rear countershaft bearing race into the
transmission gear case with Installer 8153 and Han-
dle C-4171.
(3) Install Fixture 8232 to the transmission gear
case.
NOTE: Shift socket must be loose on the shift shaft
and is rotated a minimum of 90É from its normal
position. This will ensure enough clearance to
install the transmission gear case.
(4) Attach an engine crane or equivalent to Fixture
8232 and install the transmission gear case onto the
clutch housing (Fig. 85).
(5) Install clutch housing bolts and tighten to 48
N´m (35 ft.lbs.).
(6) Install shift socket roll pin with a suitable
6mm (7/32 inch) punch and hammer.MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use
Socket 6993 to rotate the shafts and seat the bear-
ings.
(2) Measure mainshaft endplay with Dial Indicator
Set C-3339 and Extension Rod 8161 installed onto
the rear of the transmission gear case (Fig. 86).
(3) Measure countershaft end-play with Dial Indi-
cator Set C-3339 and Extension Rod 8161 installed
onto the rear of the transmission gear case (Fig. 87).
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play
of 0.051-0.15 mm (0.002-0.006 in.) for the mainshaft
and countershaft.
NOTE: Countershaft shims go between the bearing
race and spacer. Mainshaft shims go into the input
shaft retainer.
Fig. 85 Transmission Gear Case
1 - FIXTURE 8232
2 - TRANSMISSION CASE
Fig. 86 Measure Mainshaft End-Play
1 - DIAL INDICATOR C-3339
2 - EXTENSION ROD 8161
3 - MAIN SHAFT
BR/BEMANUAL - NV5600 21 - 121
MANUAL - NV5600 (Continued)

(6) Install anewinput shaft seal into the input
shaft retainer with Installer C-4965.
(7) Install input shaft oil guide with C-3972-A and
Handle C-4171.
(8) Apply sealer to the input shaft retainer and
install retainer onto the clutch housing. Install bolts
and tighten to 28 N´m (20 ft.lbs.).
REVERSE GEAR
(1) Install reverse shift fork and synchronizer as
an assembly onto the reverse shift rail and output
shaft (Fig. 88).
NOTE: Raised square shoulder and snap-ring on
the synchro face the case.
(2) Install roll-pin securing the reverse shift fork
to the reverse shift rail with 6mm (7/32 in) punch
and a hammer.
(3) Install reverse gear bearing sleeve onto the
output shaft with Installer 6446 if necessary (Fig.
89).
(4) Install reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring, and reverse
gear bearing (Fig. 90).
(5) Install output shaft ball bearing assembly and
reverse thrust washer onto the output shaft (Fig. 91).
NOTE: Raised shoulder on thrust washer faces
away from the reverse gear.(6) Install anewoutput shaft nut onto the ouput
shaft.
(7) With Wrench 8226 on the output shaft nut and
Socket 6993 or 6984 holding the output shaft, tighten
the nut to 339 N´m (250 ft.lbs.).
Fig. 87 Measure Countershaft End-Play
1 - EXTENSION ROD 8161
2 - DIAL INDICATOR C-3339
3 - COUNTERSHAFT
Fig. 88 Reverse Shift Fork and Synchro
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 89 Reverse Bearing Sleeve
1 - REVERSE GEAR BEARING SLEEVE
21 - 122 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(8) Stake nut into the slot in the output shaft with
a 9mm (5/16 in.) punch.(9) Press countershaft reverse gear into the sleeve
with a shop press.
(10) Install reverse countershaft rear bearing onto
the countershaft reverse gear assembly with Installer
C-4652 and Handle C-4171.
(11) Install reverse idler gear rear bearing, bearing
spacer, front bearing, and front thrust washer onto
the idler gear shaft.
(12) Install idler and reverse countershaft gears
together (Fig. 92).
(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 93).
Fig. 90 Reverse Gear Components
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
Fig. 91 Output Shaft Bearing and Thrust Washer
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
Fig. 92 Reverse Idler and Countershaft Gears
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 93 Crossover Cam Rollers and Pin
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
BR/BEMANUAL - NV5600 21 - 123
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)

SPECIAL TOOLS
NV5600 MANUAL TRANSMISSION
Remover, BushingÐ8155
Installer, BushingÐ8156
Handle UniversalÐC-4171
Installer, SealÐC-3972-A
Installer, SealÐ8154
Wrench, Output ShaftÐ8226
Wrench, Splined SocketÐ6984
Wrench, Splined SocketÐ6984
Puller, Bearing and GearÐ6444
BR/BEMANUAL - NV5600 21 - 127
MANUAL - NV5600 (Continued)