lock DODGE RAM 2001 Service Repair Manual

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 slow
down 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.
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 bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Remove bolts attaching shift tower and lever
assembly to rear case. Then remove shift tower and
lever assembly.
(6) Raise vehicle on hoist.
(7) Remove crankshaft position sensor. Retain sen-
sor attaching bolts.
(8) Remove skid plate, if equipped.
(9) Drain transmission lubricant if transmission
will be disassembled for service.
(10) Mark propeller shaft/shafts and yoke/yokes for
installation reference and remove propeller shaft/
shafts.
(11) Disengage harness from clips on transmission
housing.
(12) Support engine with adjustable jack stand
and wood block.
(13) Drain transmission lubricant if transmission
will be disassembled for service.
BR/BEMANUAL - NV3500 21 - 3
MANUAL - NV3500 (Continued)

TWO WHEEL DRIVE
(1) Remove nuts attaching rear mount to cross-
member (Fig. 2). Then remove insulator from exten-
sion housing if necessary.
(2) Remove bolts and nuts attaching crossmember
to frame rails. Rotate crossmember diagonally and
remove crossmember.
(3) Disconnect exhaust as necessary.
(4) Remove slave cylinder attaching nuts and
remove cylinder from clutch housing.
(5) Remove starter motor.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove nuts/bolts attaching transmission front
housing to engine.
(8) Remove transmission dust shield.
(9) Move transmission rearward until input shaft
is clear of clutch disc and cover. Then lower jack and
remove transmission from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever.
(2) Remove bolts attaching shift linkage bracket to
transfer case and move linkage and bracket aside.
(3) Support transfer case with transmission jack.
(4) Remove nuts attaching transfer case to trans-
mission adapter housing.(5) Remove transfer case with aid of helper.
(6) Support engine with a jack stand and a wood
block.
(7) Remove nuts and bolts attaching support
bracket and cushions to fixed crossmember.
(8) Remove nuts and bolts attaching removable
crossmember to frame rails.
(9) Remove crossmember.
(10) Disconnect exhaust as necessary.
(11) Remove slave cylinder attaching nuts and
remove cylinder from clutch housing. Move cylinder
aside for working clearance.
(12) Remove clutch housing dust cover.
(13) On some models, it may be necessary to
remove front axle struts and oil filter for access and
removal clearance. Remove these components if nec-
essary.
(14) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(15) Remove bolts attaching transmission clutch
housing to engine block.
(16) Move transmission rearward until transmis-
sion input shaft is clear of clutch disc and cover.
Then lower jack and remove transmission from under
vehicle.
Fig. 2 Transmission Rear Support Brackets
21 - 4 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

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)

REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 44).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and trans-
mission housings with a standard parts cleaning sol-
vent. Do not use acid or corrosive base solvents. Dry
all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such
as Mopartdegreasing solvent, Gunk, or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry, or wipe them dry
with clean shop towels.
INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball, or internal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 45). Replace any fork
exhibiting wear or damage in these areas. Do not
attempt to salvage shift forks.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks, or scores. The plunger spring should be straight
and not collapsed, or distorted. Minor scratches, or
nicks on the plunger can be smoothed with 320/400
grit emery soaked in oil. Replace the plunger and
spring if in doubt about condition. Check condition of
detent plunger bushings. Replace if damaged.
Inspect the shift shaft, shift shaft bushing and
bearing, the shaft lever, and the lever bushing that
fits over the lever. Replace the shaft if bent, cracked,
or severely scored. Minor burrs, nicks, or scratches
can be smoothed off with 320/400 grit emery cloth
followed by polishing with crocus cloth. Replace the
shift shaft bushing or bearing if damaged.
Replace the shaft lever and bushing if either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the roll
pin that secures the lever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores, or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file,
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.
Fig. 42 Fifth-Reverse Synchro
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 43 Reverse Gear And Needle Bearing
1 - REVERSE GEAR AND NEEDLE BEARING
BR/BEMANUAL - NV3500 21 - 15
MANUAL - NV3500 (Continued)

NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
front housing will have to be replaced if the coun-tershaft bearing race is loose, worn, or damaged.
The rear housing will have to be replaced if the
countershaft rear bearing race is loose, worn, or
damaged.
Fig. 44 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
Fig. 45 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
21 - 16 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(5) Start fifth-reverse synchro assembly on output
shaft splines by hand. Then seat synchro onto shaft
with shop press and Remover 6310-1 (Fig. 51).(6) Install the thickestnewfifth-reverse hub snap
ring (Fig. 52) that will fit in shaft groove. Verify snap
ring is seated in the groove.
NOTE: Snap rings are available in thicknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 in.).
(7) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 53).
Fig. 50 Reverse Gear Synchro
1 - REVERSE GEAR
2 - SYNCHRO RING
Fig. 51 Fifth-Reverse Synchro Assembly
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - REMOVER 6310-1
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
Fig. 52 Fifth-Reverse Synchro Hub Snap Ring
1 - FIFTH-REVERSE SYNCHRO ASSEMBLY
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
Fig. 53 Fifth Gear Synchro Ring
1 - FIFTH-SPEED SYNCHRO RING
2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
BR/BEMANUAL - NV3500 21 - 19
MANUAL - NV3500 (Continued)

(8) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 54).
Verify bearing is properly seated.
(9) Install fifth gear on shaft and onto bearing
(Fig. 55).
(10) Invert output shaft and set the shaft in Spe-
cial Tool 6310-1 so that fifth gear is seated on the
tool (Fig. 56).
(11) Install first gear bearing on output shaft (Fig.
56). Verify bearing is seated on shaft shoulder and is
properly joined.(12) Install first gear on shaft and over bearing
(Fig. 57). Verify bearing synchro cone is facing up as
shown.
Fig. 54 Fifth Gear Bearing
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 55 Fifth Gear
1 - FIFTH GEAR
2 - BEARING
Fig. 56 First Gear
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - SPECIAL TOOL 6310-1
4 - PRESS BLOCKS
Fig. 57 First Gear
1 - FIRST GEAR
2 - SPECIAL TOOL 6310-1
3 - BEARING
21 - 20 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(31) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 72). Ver-
ify tool presses on hub as close to output shaft as
possible but does not contact the shaft splines.
(32) Install thickestnew3-4 synchro hub snap
ring (Fig. 73) that will fit in shaft groove. Verify snap
ring is seated in groove.
NOTE: Snap rings are available in thicknesses from
2.00 - 2.30 mm (0.078 - 0.090 in.).(33) Install output shaft bearing.
(34) Install output shaft bearing snap ring with
heavy duty snap ring pliers (Fig. 74). Verify snap
ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
(35) Verify position of synchro sleeves before pro-
ceeding (Fig. 75). Grooved side of 3-4 sleeve must be
facing forward. First gear side of 1-2 sleeve must be
facing first gear. Tapered side of fifth-reverse sleeve
must be facing forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube.
(2) Slide idler gear bearing on shaft (Fig. 76).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 76).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 76). Petroleum jelly can be used to
hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 77).
(6) Install snap ring in groove at rear of shaft (Fig.
77).
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
Fig. 72 Press 3-4 Synchro On Output Shaft
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 73 3-4 Synchro Hub Snap Ring
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 74 Output Shaft Bearing Snap
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
BR/BEMANUAL - NV3500 21 - 25
MANUAL - NV3500 (Continued)

Fig. 75 Synchro Sleeve Locations
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCHRO SLEEVE
8 - 3-4 SYNCHRO SLEEVE
Fig. 76 Idler Gear And Bearing
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFTFig. 77 Idler Gear Rear Thrust Washer
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
21 - 26 MANUAL - NV3500BR/BE
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)