DODGE RAM 2002 Service Repair Manual

COUNTERSHAFT
(1) Place third countershaft gear on the bench
with the synchro clutch ring up.
(2) Install third countershaft gear friction cone
onto third gear (Fig. 68).
(3) Install third countershaft gear blocker ring
onto the friction cone (Fig. 69).(4) Install 3-4 synchro assembly onto the blocker
ring/gear assembly (Fig. 70).
(5) Reverse the assembly on the bench.
(6) Install third countershaft gear bearing into the
third countershaft gear.
(7) Install 2-3 thrust washer onto the countershaft.
(8) Place third gear/3-4 synchro assembly in a shop
press.
(9) Install countershaft through the third gear/3-4
synchro assembly.
(10) Press countershaft into the 3-4 synchro
assembly (Fig. 71).
(11) Install fourth countershaft gear bearing sleeve
onto the output shaft.
Fig. 67 OUTPUT SHAFT POCKET BEARING
1 - GUIDE
2 - POCKET BEARING
Fig. 68 FRICTION CONE ONTO GEAR
1 - FRICTION CONE
2 - GEAR
3 - CLUTCH RING
Fig. 69 BLOCKER RING ONTO FRICTION CONE
1 - BLOCKER RING
2 - GEAR
3 - FRICTION CONE
Fig. 70 3-4 SYNCHRO ASSEMBLY
1 - SYNCHRO
2 - GEAR
21 - 68 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(12) Press fourth countershaft bearing sleeve onto
the countershaft with Installer 8228 and a shop
press.
(13) Place fourth countershaft gear on the bench
with the synchro clutch ring up.
(14) Install fourth countershaft gear friction cone
onto fourth countershaft gear (Fig. 68).
(15) Install fourth countershaft gear blocker ring
onto the friction cone (Fig. 69).
(16) Install fourth countershaft gear bearing into
the fourth countershaft gear.
(17) Place sixth countershaft gear in the shop
press.
(18) Position fourth countershaft gear assembly
onto the sixth countershaft gear (Fig. 72).
(19) Install countershaft into the fourth/sixth coun-
tershaft gear assembly in the shop press.
(20) Press countershaft into sixth gear (Fig. 73).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.
(21) Place fifth countershaft gear into the shop
press.
Fig. 71 COUNTERSHAFT INTO 3-4 SYNCHRO
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR
Fig. 72 FOURTH COUNTERSHAFT ONTO SIXTH
COUNTERSHAFT GEAR
1 - FOURTH BEARING
2 - FOURTH COUNTERSHAFT GEAR
3 - SIXTH COUNTERSHAFT GEAR
Fig. 73 COUNTERSHAFT TO SIXTH
COUNTERSHAFT GEAR
1 - COUNTERSHAFT
2 - SIXTH COUNTERSHAFT GEAR
3 - 3-4 SYNCHRO
BR/BEMANUAL - NV5600 21 - 69
MANUAL - NV5600 (Continued)

(22) Install countershaft into the fifth countershaft
gear and press countershaft into fifth gear (Fig. 74).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.
(23) Place front countershaft bearing onto the
countershaft.
(24) Install front countershaft bearing onto the
countershaft with Installer 8236 and Handle C-4171.
(25) Install anewsnap-ring to hold the front
countershaft bearing onto the countershaft.
(26) Place rear countershaft bearing onto the coun-
tershaft.INPUT SHAFT
(1) Place the input shaft bearing onto the input
shaft.
(2) Install input shaft bearing with Installer
MD998805 (Fig. 75).
(3) Position the input shaft bearing oil guide on
the input shaft (Fig. 76).
(4) Install input shaft bearing oil guide with
Installer MD998805.
(5) Place the output shaft pocket bearing race in
the input shaft.
(6) Install output shaft pocket bearing race into
the input shaft with Installer C-4628 and Handle
C-4171 (Fig. 77).
Fig. 74 COUNTERSHAFT TO FIFTH
COUNTERSHAFT GEAR
1 - COUNTERSHAFT
2 - FIFTH COUNTERSHAFT GEAR
Fig. 75 INPUT SHAFT BEARING
1 - INSTALLER
2 - INPUT SHAFT BEARING
21 - 70 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

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
2 - INPUT SHAFT
3 - INSTALLER
Fig. 78 OIL GUIDE AND SPACER
1 - 0.3 IN. BEYOND FLUSH
2 - 0.4 IN. BEYOND FLUSH
BR/BEMANUAL - NV5600 21 - 71
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
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 a engine crane or equivalent to Fixture
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.
(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 and
tighten to 28 N´m (20 ft. lbs.) (Fig. 84).
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
Fig. 79 OUTPUT SHAFT AND INPUT SHAFT
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND
Fig. 80 COUNTERSHAFT TO MAINSHAFT
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND
21 - 72 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.
Fig. 81 LIFT GEARTRAIN
1 - FIXTURE
2 - SUPPORT STAND
Fig. 82 INSTALL SHIFT RAILS
1 - SHIFT RAILS
Fig. 83 HOLDING TOOL
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 84 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKET
BR/BEMANUAL - NV5600 21 - 73
MANUAL - NV5600 (Continued)

(4) Apply sealant to the clutch housing.
(5) Attach an engine crane or equivalent to Fixture
8232 and install the transmission gear case onto the
clutch housing (Fig. 85).
(6) Install clutch housing bolts and tighten to 48
N´m (35 ft.lbs.).
(7) 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.
(6) Install anewinput shaft seal into the input
shaft retainer with Installer C-4965.
Fig. 85 TRANSMISSION GEAR CASE
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 86 MAINSHAFT END-PLAY
1 - DIAL INDICATOR
2 - EXTENSION ROD
3 - MAIN SHAFT
Fig. 87 COUNTERSHAFT END-PLAY
1 - EXTENSION ROD
2 - DIAL INDICATOR
3 - COUNTERSHAFT
21 - 74 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(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.).
(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).
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.
Fig. 88 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 89 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
BR/BEMANUAL - NV5600 21 - 75
MANUAL - NV5600 (Continued)

(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.
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
21 - 76 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(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 into the exten-
sion/adapter housing and tighten 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).
(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.).
Fig. 94 MEASURE HEIGHT OF REVERSE
COUNTERSHAFT
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
Fig. 95 REVERSE COUNTERSHAFT GEAR BEARING
RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
Fig. 96 CROSSOVER CAM
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
BR/BEMANUAL - NV5600 21 - 77
MANUAL - NV5600 (Continued)