Nv3500 DODGE RAM 2001 Service Repair Manual

FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
1500 Series with 6.5'
Short Box98 L (26 gal.)*****
2500 Series Club Cab
and Quad Cab with 6.5'
Short Box129 L (34 gal.)*****
All 8' Long Box 132 L (35 gal.)*****
All Cab/Chassis Models 132 L (35 gal.)*****
ENGINE OIL WITH FILTER
3.9L 4.2 L (4.5 qts.)
5.2L 4.7 L (5.0 qts.)
5.9L 4.7 L (5.0 qts.)
8.0L 6.6 L (7.0 qts.)
5.9L DIESEL 10.4 L (11.0 qts.)
COOLING SYSTEM
3.9L 19 L (20 qts.)****
5.2L 19 L (20 qts.)****
5.9L 19 L (20 qts.)****
8.0L 24.5 L (26.0 qts.)****
5.9L DIESEL 22.7 L (24.0 qts.)****
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal cooler,
length and inside diameter of cooler lines, or use of an
auxiliary cooler, these capacities may vary. Refer to
19, Steering for proper fill and bleed procedures.
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8 L (4.0 qts.)
O-haul - 42RE 9-9.5 L (19-20 pts.)*
Service Fill - 44RE 3.8 L (4.0 qts.)
O-haul - 44RE 9-9.5 L (19-20 pts.)*
Service Fill - 46RE 3.8 L (4.0 qts.)
O-haul - 46RE 9-9.5 L (19-20 pts.)*
Service Fill - 47RE 3.8 L (4.0 qts.)
O-haul - 47RE 14-16 L 29-33 pts.)*
DESCRIPTION SPECIFICATION
Dry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these figures may vary. Refer
to 21, Transmission for proper fluid fill procedure.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV3500 2.0 L (4.2 pts.)
NV4500 3.8 L (8.0 pts.)
NV4500 HD 3.8 L (8.0 pts.)
NV5600 4.5 L (9.5 pts.)
TRANSFER CASE
NV231 HD 1.2 L (2.5 pts.)
NV241 2.18 L (4.61 pts.)
NV241 HD 3.08 L (6.51 pts.)
FRONT AXLE
Model 216-FBI 2.3 L (4.8 pts.)
Model 248-FBI 4.0L (8.5 pts.)
REAR AXLE
9-1/4 inch 2.1 L (4.5 pts.)
248-RBI(2WD) 3.0 L (6.3 pts.)
248-RBI(4WD) 3.4L (7.0 pts.)
267-RBI(2WD) 3.3 L (7.0 pts.)
267-RBI (4WD) 3.6L (7.5 pts.)
286-RBI (2WD) 3.2 L (6.8 pts.)
286-RBI (4WD) 4.8 L (10.1 pts.)
REAR AXLEÐLIMITED SLIP DIFFERENTIAL
9-1/4 inch 2.2 L (4.7 pts.)6
248-RBI (2WD) 3.0 L (6.3 pts.**)
248-RBI (4WD) 3.4 L (7.0 pts.)
267-RBI 3.3 L (7.0 pts.**)
267-RBI (4WD) 3.6 L (7.5 pts.)
286-RBI (2WD) 3.2 L (6.8 pts.**)
286-RBI (4WD) 4.8 L (10.1 pts.***)
** Include 0.05 L (0.25 pts.) friction modifier.
*** Include 0.19 L (0.4 pts.) friction modifier.
6Include 0.1 L (0.2 pts.) friction modifier.
**** Includes 0.9L (1.0 qts.) for coolant reservoir.
*****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
0 - 6 LUBRICATION & MAINTENANCEBR/BE

CLUTCH HOUSING
DIAGNOSIS AND TESTING - CLUTCH HOUSING
Clutch housing alignment is important to proper
clutch operation. The housing maintains alignment
between the crankshaft and transmission input
shaft. Misalignment can cause clutch noise, hard
shifting, incomplete release and chatter. It can also
result in premature wear of the pilot bearing, cover
release fingers and clutch disc. In severe cases, mis-
alignment can also cause premature wear of the
transmission input shaft and front bearing.
Housing misalignment is generally caused by
incorrect seating on the engine or transmission, loose
housing bolts, missing alignment dowels, or housing
damage. Infrequently, misalignment may also be
caused by housing mounting surfaces that are not
completely parallel. Misalignment can be corrected
with shims.
CHECKING RUNOUT
Only the NV4500 clutch housing can be
checked using the following bore and face
runout procedures. The NV3500 and NV5600
clutch housings are an integral part of the
transmission and can only be checked off the
vehicle.
MEASURING CLUTCH HOUSING BORE RUNOUT
(1) Remove the clutch housing and strut.
(2) Remove the clutch cover and disc.
(3) Replace one of the flywheel bolts with an
appropriate size threaded rod that is 10 in. (25.4 cm)
long (Fig. 14). The rod will be used to mount the dial
indicator.(4) Remove the release fork from the clutch hous-
ing.
(5) Reinstall the clutch housing. Tighten the hous-
ing bolts nearest the alignment dowels first.
(6) Mount the dial indicator on the threaded rod
and position the indicator plunger on the surface of
the clutch housing bore (Fig. 15).
(7) Rotate the crankshaft until the indicator
plunger is at the top center of the housing bore. Zero
the indicator at this point.
(8) Rotate the crankshaft and record the indicator
readings at eight points (45É apart) around the bore
(Fig. 15). Repeat the measurement at least twice for
accuracy.
(9) Subtract each reading from the one 180É oppo-
site to determine magnitude and direction of runout.
Refer to (Fig. 16) and following example.
Bore runout example:
0.000 ± (±0.007) = 0.007 in.
+0.002 ± (±0.010) = 0.012 in.
+0.004 ± (±0.005) = 0.009 in.
±0.001 ± (+0.001) = ±0.002 in. (= 0.002 inch)
In the above example, the largest difference is
0.012 in. and is called the total indicator reading
(TIR). This means that the housing bore is offset
from the crankshaft centerline by 0.006 in. (which is
1/2 of 0.012 in.).
Fig. 14 Dial Indicator Mounting Stud Or Rod
1 - 7/16 - 20 THREAD
2 - NUT
3 - STUD OR THREADED ROD
4 - 10 INCHES LONG
Fig. 15 Checking Clutch Housing Bore Runout
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
BR/BECLUTCH 6 - 11

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV3500........................1
MANUAL - NV4500.......................44
MANUAL - NV5600.......................91
AUTOMATIC TRANSMISSION - 42RE........134
AUTOMATIC TRANSMISSION - 44RE........305AUTOMATIC TRANSMISSION - 46RE........477
AUTOMATIC TRANSMISSION - 47RE........648
TRANSFER CASE - NV231HD..............820
TRANSFER CASE - NV241LD..............855
TRANSFER CASE - NV241HD..............890
MANUAL - NV3500
TABLE OF CONTENTS
page page
MANUAL - NV3500
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................3
MANUAL TRANSMISSION.................3
REMOVAL...............................3
DISASSEMBLY............................5CLEANING..............................15
INSPECTION............................15
ASSEMBLY.............................17
INSTALLATION...........................40
SPECIFICATIONS........................41
SPECIAL TOOLS.........................41
MANUAL - NV3500
DESCRIPTION
The NV3500 is a medium-duty 5-speed, constant
mesh fully synchronized manual transmission. Fifth
gear is an overdrive range with a ratio of 0.73:1. The
NV3500 is available in two and four-wheel drive con-
figurations.
The transmission gear case consists of two alumi-
num housings (Fig. 1). The clutch housing is not a
removable component. It is an integral part of the
transmission front housing.
A combination of roller and ball bearings are used
to support the transmission shafts in the two hous-
ings. The transmission gears all rotate on caged type
needle bearings. A roller bearing is used between the
input and output shaft.
The transmission has a single shaft shift mecha-
nism with three shift forks all mounted on the shaft.
The shaft is supported in the front and rear housings
by bushings and one linear ball bearing. Internal
shift components consist of the forks, shaft, shift
lever socket, and detent components
GEAR RATIOS
Gear ratios is as follows:
GEAR RATIO
FIRST 4.02:1
SECOND 2.32:1
THIRD 1.40:1
FOURTH 1:1
FIFTH 0.73:1
REVERSE 3.55:1
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.
BR/BETRANSMISSION AND TRANSFER CASE 21 - 1

Fig. 1 NV3500 Manual Transmission
21 - 2 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

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)

(10) Remove shift shaft detent plug with Remover
8117A. Attach fingers of the remover to the detent
plug and push the cup down till it contacts the trans.
Then tighten the nut till it pulls the plug from the
case.
(11) Remove shift shaft detent plunger and spring
with a pencil magnet.
(12) Remove bolts that attach front housing to rear
housing (Fig. 9). Three bolts at extreme rear of hous-
ing are actually for the output shaft bearing retainer.
It is not necessary to remove all three bolts at this
time. Leave at least one bolt in place until geartrain
is ready to be removed from case.
(13) Separate front housing from rear housing
(Fig. 10). Use plastic hammer to tap front housing off
alignment dowels.
(14) Remove and inspect input shaft bearing.
Inspect countershaft front bearing race (Fig. 11).
Fig. 7 Input Shaft Bearing Retainer
1 - SHAFT BEARING
2 - BEARING RETAINER
3 - INPUT SHAFT
Fig. 8 Input Shaft
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
Fig. 9 Housing And Bearing Retainer Bolt
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
Fig. 10 Front Housing
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
21 - 6 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(15) Note position of input shaft, shift shaft and
forks, and geartrain components in housing (Fig. 12).
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Unseat shift socket roll pin with Remover 6858.
Position remover on shift shaft and center tool over
the roll pin. Verify tool legs are firmly seated on the
shift socket (Fig. 13).
(2) Tilt socket toward the side of the case to avoid
trapping the pin between the gear teeth.
(3) Tighten remover to press the roll pin down-
ward and out of the shift socket (Fig. 13).
NOTE: Roll pin does not have to be completely
removed, the pin must only be clear of the shift
shaft. Be careful not to push the pin into the
geartrain.
(4) Drive out shift bushing and lever roll pint with
a hammer and punch (Fig. 14).
NOTE: Use proper size punch to avoid bending the
shift shaft.
(5) Pull shift shaft straight out of rear housing,
shift socket, fifth-reverse fork and 1-2 fork (Fig. 15).
(6) Remove shift socket from rear housing (Fig.
16).
(7) Remove lever and bushing (Fig. 17).
(8) Remove 3-4 fork. Rotate 3-4 fork around syn-
chro sleeve until fork clears shift arms on 1-2 and
fifth-reverse forks. Then remove 3-4 fork (Fig. 18).
Fig. 11 Input Shaft Bearing and Countershaft Front
Bearing Race
1 - INPUT SHAFT BEARING
2 - FRONT HOUSING
3 - COUNTERSHAFT FRONT BEARING
Fig. 12 Geartrain And Shift Components
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
Fig. 13 Shift Socket
1 - REMOVER 6858
2 - SHIFT SOCKET
BR/BEMANUAL - NV3500 21 - 7
MANUAL - NV3500 (Continued)

(9) Remove the reverse idler shaft support bolt
(front bolt) (Fig. 19).
(10) Loosen rear reverse idler shaft bolt (rear bolt)
(Fig. 19).
(11) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(12) Support geartrain and rear housing on Fix-
ture 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2B on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 20).
(d) Stand geartrain and rear housing upright on
fixture (Fig. 21). Have helper hold fixture tool in
place while housing and geartrain is being rotated
into upright position.
Fig. 14 Shift Shaft Lever And Bushing Roll Pin
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 15 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 16 Shift Socket And Roll
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 17 Shift Shaft Lever And Bushing
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 18 3-4 Shift Fork
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
21 - 8 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)