lock DODGE RAM 2001 Service Repair Manual

(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)

CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-
mission will have to be disassembled again to cor-
rect shaft alignment.
(9) Select correctnewroll pin for shift shaft lever
(Fig. 104). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 105).(11) Seat shaft lever roll pin with pin punch (Fig.
106).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 106).
(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 107).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket after installation
(Fig. 108).
(15) Verify that notches in shift fork arms are
aligned. Realign arms if necessary.
Fig. 102 Inserting Shaft Into Lever Opening
1 - SHIFT SHAFT
Fig. 103 Shift Socket
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 104 Roll Pin Identification
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 105 Roll Pin In Shift Socket
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
BR/BEMANUAL - NV3500 21 - 35
MANUAL - NV3500 (Continued)

FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) If previously removed, install input shaft bear-
ing in front housing bore (Fig. 109). Install snap ring
and use plastic mallet to seat bearing. Bearing goes
in from front side of housing only.
(2) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 109). Large diameter side of
bearing cage goes toward countershaft (Fig. 110).
Small diameter side goes toward bearing race in
housing.(3) Reach into countershaft front bearing with fin-
ger and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
Fig. 106 Shift Shaft Lever Roll
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 107 Roll Pin In Shift Socket
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 108 Seat Shift Socket
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
Fig. 109 Input Shaft Bearing And Countershaft Front
Bearing
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
21 - 36 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)

SHIFT PATTERN
The shift pattern is in a modified H pattern (Fig.
2). Overdrive fifth and reverse gears are in line and
outboard of the first through fourth gear positions.
GEAR RATIOS
GEAR RATIO
FIRST 5.61:1
SECOND 3.04:1
THIRD 1.67:1
FOURTH 1.00:1
FIFTH 0.75:1
REVERSE 5.04:1
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 3).
The tag provides the transmission model number,
build date and part number. Be sure to reinstall the
I.D. tag if removed during service. The information
on the tag is essential to correct parts ordering.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point, all the transmission gears
are spinning.
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 slowdown 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.
Fig. 2 NV4500
Fig. 3 Identification Tag Location
1 - PTO COVER
2 - I.D. TAG
21 - 46 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

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 screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
Fig. 4 NV4500 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
BR/BEMANUAL - NV4500 21 - 47
MANUAL - NV4500 (Continued)

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 27).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 28).
(4) Roll gear case onto left side (Fig. 29).
(5) To remove mainshaft assembly (Fig. 29) lift
front end of mainshaft slightly.
NOTE: Handling mainshaft carfully because gears
are lose on the mainshaft.
(6) Grasp mainshaft rear splines, then turn spline
end of mainshaft counterclockwise to rotate shaft and
geartrain out of case. Tilt mainshaft outward and
removed from case.
Fig. 25 Pilot Bearing
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 26 Front Bearing Puller
1 - PULLER 6444
2 - RODS 6444-6
3 - JAWS 6447
4 - COLLAR 6444-8
5 - FLANGE 6444-1
6 - DRIVE GEAR
Fig. 27 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 28 Fourth Gear Clutch Gear Stop Ring
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
21 - 54 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

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 worn
fork. 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 NV4500 trans-
mission. Use MoparTSilicone Sealer or equivalent
on all gear case and extension housing sealing sur-
faces.
COUNTERSHAFT AND REVERSE IDLER GEAR
(1) Install countershaft front bearing cup in case
with Handle C-4171 and Installer 6061-1.
(2) Install front bearing on countershaft with
Installer C-4340 (Fig. 64).
(3) Lubricate countershaft front bearing cup and
cone with petroleum jelly.
(4) Position gear case on end with rear of case fac-
ing up (Fig. 65).
(5) Install countershaft in gear case (Fig. 65).
NOTE: Do not install rear countershaft bearing on
countershaft at this time.
Fig. 64 Countershaft Front Bearing
1 - FRONT BEARING
2 - INSTALLER C-4340
3 - COUNTERSHAFT
BR/BEMANUAL - NV4500 21 - 65
MANUAL - NV4500 (Continued)

(12) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 69).
(13) Install rear bearing cone on countershaft with
Installer C-4040 (Fig. 70).
(14) Remove wood block from under countershaft
and lower countershaft front bearing into front bear-
ing cup.(15) Lubricate countershaft rear bearing cup and
cone with petroleum jelly.
(16) Install countershaft rear bearing cup in gear
case and over rear bearing (Fig. 71). Tap cup into
place with plastic mallet if necessary.
(17) Install countershaft rear bearing plate (Fig.
72).
NOTE: Verify plate is seated in notch in reverse
idler shaft before tightening bearing plate bolts.
Fig. 69 Supporting Countershaft With Wood Block
1 - COUNTERSHAFT
2 - WOOD BLOCK
Fig. 70 Countershaft Rear Bearing
1 - INSTALLER C-4040
2 - REAR BEARING
3 - COUNTERSHAFT
Fig. 71 Countershaft Rear Bearing Cup
1 - COUNTERSHAFT REAR BEARING CUP
Fig. 72 Countershaft Rear Bearing Plate
1 - COUNTERSHAFT
2 - REAR BEARING PLATE
3 - IDLER SHAFT
BR/BEMANUAL - NV4500 21 - 67
MANUAL - NV4500 (Continued)