transmission DODGE RAM 2002 Service Repair Manual

(18) Remove mainshaft rear bearing plate bolts
and remove fifth gear plate end play shims and bear-
ing cup (Fig. 18).
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 19). Do not reused retainer bolts.(2) Lightly tapping retainer back and forth with
plastic mallet. Then rock retainer back and forth by
hand to work it out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
(3) Remove front retainer seal by (Fig. 20) collaps-
ing one side of seal then prying it out.
(4) To remove front retainer bearing cup, assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
21).
(5) Insert Puller Jaws 6453-1 in puller flange (Fig.
21). Narrow lip of puller jaws will go under bearing
cup.
(6) Install Disc C-4487-1 into bearing retainer on
heavy duty transmissions for Insert 6453-2 to rest
upon.
Fig. 16 Retaining Collar Over Puller Jaws
1 - JAWS 6459 or 6820
2 - COLLAR 6444-8
Fig. 17 Fifth Gear From Mainshaft Splines
1 - COLLAR 6444-8
2 - JAWS 6459 OR 6820
3 - BOLT 6444
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE 6444-1
Fig. 18 Mainshaft Fifth Gear Bearing Plate, Bearing
Shims And Rear Bearing Cup
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 19 Front Bearing Retainer
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
21 - 8 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

ASSEMBLY
NOTE: Gaskets are not used in the transmission.
Use Mopar Silicone Sealer or equivalent on all gear
case and extension housing sealing surfaces.
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.
(6) Lubricate reverse idler gear bearings with
petroleum jelly and install first bearing and second
bearing (Fig. 66).
(7) Install idler gear front thrust washer on boss
in gear case (Fig. 66). Coat thrust washer with lib-
eral quantity of petroleum jelly to hold it in place.
(8) Install reverse idler gear in case (Fig. 67).
(9) Install idler gear rear thrust washer between
idler gear and case boss (Fig. 67).
(10) Align idler gear bearings and thrust washers
with a drift.
(11) Install reverse idler shaft with notched end of
shaft facing countershaft (Fig. 68).
Fig. 64 Countershaft Front Bearing
1 - FRONT BEARING
2 - INSTALLER C-4340
3 - COUNTERSHAFT
Fig. 65 Countershaft In Gear Case
1 - GEAR CASE
2 - COUNTERSHAFT
Fig. 66 Idler Gear Front Thrust Washer
1 - POSITION IDLER GEAR FRONT THRUST WASHER ON
BOSS
BR/BEMANUAL - NV4500 21 - 21
MANUAL - NV4500 (Continued)

(37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 105).(38) Install fourth gear clutch gear in stop ring
(Fig. 106).
(39) Roll gear case onto its left side.
(40) Grip mainshaft at pilot bearing hub and just
behind reverse gear. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
(41) Continue holding front of shaft but switch
grip at rear to shaft output splines. Lift mainshaft
assembly slightly, align gears and seat assembly in
case.
(42) Set transmission case upright (Fig. 107).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 108). Use plenty of petroleum jelly to hold bear-
ing in place.
(44) Check alignment and mesh of mainshaft
gears. If gears are not aligned, roll case on side and
realign shaft and gears in case.
Fig. 103 Reverse Gear Thrust Washer
1 - THRUST WASHER
2 - REVERSE GEAR
Fig. 104 Mainshaft Rear Bearing
1 - INSTALLER 6446
2 - MAINSHAFT REAR BEARING
Fig. 105 Fourth gear Stop Ring
1 - 3-4 SYNCHRO SLEEVE
2 - FOURTH SPEED STOP RING
Fig. 106 Fourth gear Clutch Gear
1 - FOURTH SPEED CLUTCH GEAR
Fig. 107 Mainshaft And Geartrain In Case
1 - MAINSHAFT AND GEARTRAIN
2 - FOURTH SPEED CLUTCH GEAR
BR/BEMANUAL - NV4500 21 - 31
MANUAL - NV4500 (Continued)

MAINSHAFT END PLAY
(1) Install mainshaft rear bearing cup in case and
over bearing. Tap bearing cup into place with plastic
mallet.
(2) Install rear bearing plate to hold mainshaft
and rear bearing in position (Fig. 114).
NOTE: Do not install any end play shims at this
time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case in upright position on bench.
Either cut hole in bench to accept drive gear and
front retainer or use C-clamps to secure transmission
on bench.
NOTE: Do not leave transmission unsupported.
(5) Install Extension Rod 8161 into a suitable
threaded hole in rear of case.(6) Mount dial indicator on extension rod and posi-
tion indicator plunger against end of mainshaft.
(7) Move mainshaft forward to remove all play
then zero dial indicator.
(8) Move mainshaft upward and record dial indica-
tor reading. Move mainshaft with pry tool positioned
between drive gear and case.
(9) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play.
If end play adjustment is required, remove bearing
plate and install necessary shim.
(10) Reinstall rear bearing plate with oil hole in
bearing plate at the top (Fig. 114).
(11) Apply Mopar Lock N' Seal or equivalent to
bearing plate bolt threads. Install and tighten bolts
to 23 N´m (200 in. lbs.).
(12) Install mainshaft fifth gear with Installer
6446 (Fig. 115). Gear is seated when it contacts rear
bearing.
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) Install thrust washer pin in countershaft (Fig.
116).
(2) Install thrust washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 117).
NOTE: The flat side of washer faces the rear and
cone side faces the front.
(3) Lubricate and install fifth gear bearing on
countershaft (Fig. 118).
(4) Install synchro sleeve on hub of countershaft
fifth gear with tapered side of sleeve facing front and
the flat side facing rear (Fig. 119).
(5) Install shift fork in synchro sleeve (Fig. 120).
Fig. 112 Location Of Front Retainer Lube Channel
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 113 Front Bearing Retainer
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
Fig. 114 Rear Bearing Plate
1 - BEARING PLATE OIL HOLE (AT TOP)
2 - MAINSHAFT REAR BEARING PLATE
BR/BEMANUAL - NV4500 21 - 33
MANUAL - NV4500 (Continued)

(7) Hold mainshaft Socket 6993 4X2 or Socket
6984 4X4 while installing the fifth gear nut.
(8) Tighten fifth gear nut as much as possible with
Nut Wrench 6743, long handle ratchet, breaker bar
and applicable socket wrench (Fig. 126).
(9) Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
(10) Tighten fifth gear nut with Nut Wrench 6743
and high capacity torque wrench. Tighten nut to 366-380 N´m (270-280 ft. lbs.). Have helper hold trans-
mission steady if necessary.
(11) Torque the fifth gear clamp nut clamping bolt
to 13.5 N´m (10 ft. lbs.).
(12) Unlock the mainshaft gears by shifting all
synchro sleeves out of the engaged position.
EXTENSION/ADAPTER HOUSING
(1) Clean mating surfaces of extension/adapter
housing and gear case with a wax and grease
remover.
(2) Check alignment dowels in gear case and hous-
ing or adapter. Be sure dowels are in position and
seated.
(3) Apply Mopar Silicone Sealer or equivalent to
gear case and housing mating surfaces.
(4) Align and install extension/adapter housing on
gear case (Fig. 127).
(5) Apply Mopar Lock N' Seal or equivalent to
threads of extension/adapter housing bolts.
(6) Install and tighten housing bolts to 54 N´m (40
ft. lbs.).
(7) Install transfer case, if equipped.
(8) Install engine rear support.
(9) Install propeller shaft(s).
(10) Remove transmission support stand and lower
vehicle.
Fig. 125 Fifth Gear Nut
1 - FIFTH GEAR
2 - FIFTH GEAR NUT
Fig. 126 Fifth Gear Nut
1 - WRENCH 6443 OR 6743
2 - FIFTH GEAR NUT
3 - SOCKET 6993 OR 6984
Fig. 127 Installing Extension/Adapter Housing
1 - GEAR CASE
2 - EXTENSION HOUSING
21 - 36 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

INSTALLATION
NOTE: If a new transmission is being installed, 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.
(1) Apply light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
the following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
(4) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start input
shaft in release bearing, clutch disc and pilot bush-
ing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-clutch hous-
ing bolts to 108 N´m (80 ft. lbs.).
(8) Install transmission mount on transmission or
rear crossmember.
(9) Install rear crossmember.
(10) Remove transmission jack and engine support
fixture.
(11) Position transmission harness wires in clips
on shift cover.
(12) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(13) Connect speed sensor and backup light switch
wires.
TWO WHEEL DRIVE
(1) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(2) Align and install propeller shaft.
(3) Lower vehicle.
(4) Clean the mating surfaces of shift tower, isola-
tor plate and shift cover with suitable wax and
grease remover.
(5) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.(6) Install the isolator plate onto the shift cover,
metal side down.
(7) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(8) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(9) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(10) Install the shift lever extension onto the shift
tower and lever assembly.
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install transfer case shift mechanism on trans-
mission.
(2) Install transfer case on transmission jack.
Secure transfer case to jack with safety chains.
(3) Raise jack and align transfer case input gear
with transmission mainshaft.
(4) Move transfer case forward and seat it on
adapter.
(5) Install and tighten transfer case attaching
nuts. Tighten nuts to 41-47 N´m (30-35 ft. lbs.) if
case has 3/8 studs or 30-41 N´m (22-30 ft. lbs.) if case
has 5/16 studs.
(6) Install transfer case shift mechanism to side of
transfer case.
(7) Connect transfer case shift lever to range lever
on transfer case.
(8) Align and connect propeller shafts.
(9) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(10) Install transfer case skid plate, if equipped
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(11) Install exhaust system components.
(12) Lower vehicle.
(13) Clean the mating surfaces of shift tower, iso-
lator plate and shift cover with suitable wax and
grease remover.
(14) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(15) Install the isolator plate onto the shift cover,
metal side down.
(16) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(17) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
BR/BEMANUAL - NV4500 21 - 37
MANUAL - NV4500 (Continued)

ADAPTER HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support vehicle.
(2) Mark the propeller shafts and yokes for instal-
lation reference and remove the shafts.
(3) Support transmission with a transmission jack.
(4) Remove engine rear support.
(5) Remove transfer case.
(6) Remove adapter housing seal with a pry tool or
slide hammer mounted screw (Fig. 128).
INSTALLATION
(1) Install adapter housing seal with Installer
C-3860-A and Handle C-4171.
(2) Install transfer case.
(3) Install propeller shafts with reference marks
aligned.
(4) Fill transfer case and transmission to proper
level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the propeller shaft and yoke for installa-
tion reference.
(3) Remove the propeller shaft.
(4) Remove extension housing seal (Fig. 129) using
Remover C-3985-B.(5) On heavy duty 4X2 vehicles, remove extension
housing seal with a pry tool or a slide hammer
mounted screw.
(6) On light duty transmissions, remove the exten-
sion housing bushing with Remover 6957.
(7) On heavy duty transmissions, remove the
extension housing bushing with Remover 8155.
INSTALLATION
(1) Install housing bushing with Handle C-4171
(Fig. 130) and Installer.
²Light Duty - Installer 6951
²Heavy Duty - Installer 8161
(2) Install housing seal with Handle C-4171 (Fig.
131) and Installer.
²Light Duty - Installer C-3972-A
²Heavy Duty - Installer 8154
(3) Install propeller shaft with reference marks
aligned.
Fig. 128 Adapter Housing - 4WD
1 - ADAPTER HOUSING
2 - SEAL
Fig. 129 Extension Housing - 2WD
1 - EXTENSION HOUSING
2 - SEAL
Fig. 130 Extension Housing Bushing
1 - HANDLE C-4171
2 - INSTALLER
3 - EXTENSION HOUSING
21 - 42 MANUAL - NV4500BR/BE

(4) Check and fill transmission.
(5) Remove support and lower vehicle.
SHIFT MECHANISM - NV4500
REMOVAL
(1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 132).
(3) Pry up shift cover at slots provided in cover
(Fig. 133).
(4) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 134).
(5) Raise front of shift cover and lift cover up and
off gear case (Fig. 134).
FIFTH-REVERSE SHIFT FORK PADS
Three shift pads on the forks are held in place by
tension and a small locating tang (Fig. 135).
To remove the pads, grasp a pad with hand and tilt
it out and off the fork. If pad is difficult to remove by
hand, insert a screwdriver blade between the pad
and fork and pry the pad off.
EXPANSION PLUG
The expansion plugs at the rear of the shift rail
bores (Fig. 136) can be replaced if loose/leaking.
(1) Drill 6 mm (1/4 in.) diameter hole in center of
the plug to be removed.
(2) Pry plug out of cover with tapered punch.
Fig. 131 Extension Housing Seal
1 - HANDLE C-4171
2 - INSTALLER
Fig. 132 Shift Cover Bolts
1 - SHIFT COVER
2 - BOLTS
Fig. 133 Loosening Shift Cover
1 - SHIFT COVER SLOT
2-PRYTOOL
Fig. 134 Shift Cover
1 - SHIFT COVER
2 - ALIGNMENT DOWELS
BR/BEMANUAL - NV4500 21 - 43
EXTENSION HOUSING SEAL - NV4500 (Continued)

(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of Mopar silicone sealer or
equivalent to outer edge of each new plug.
(2) Position each plug in bore and tap into place
with hammer and punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab.
(2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift cover and gear
case with wax and grease remover.(2) Apply a small amount of Mopar silicone sealer
or equivalent to sealing surface of shift cover.
CAUTION: Do not over-apply an excesive amount
sealer. Excess can squeezed into gear case and
could block lubricant feed holes in time.
(3) Lubricate synchro sleeves with CastroltSyn-
torq gear lubricant or equivalent. Then apply light
coat of petroleum jelly to shift fork contact surfaces.
(4) Verify shift fork pads (Fig. 137) are secure.
(5) Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
(6) Align and seat shift cover on transmission.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
(7) Apply Mopar Lock N' Seal or equivalent to
threads of shift cover bolts.
(8) Install shift cover bolts and tighten to 27-31
N´m (216-276 in. lbs.).
(9) Apply sealer to backup lamp switch. Install
switch into cover and tighten to 22-34 N´m (193-265
in. lbs.).
(10) Install vent assembly if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
(11) Install transmission.
Fig. 135 Shift Fork Pad Locations
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
Fig. 136 Expansion Plug Location
1 - EXPANSION PLUGS
Fig. 137 Fifth-Reverse Shift Fork Pads
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
21 - 44 MANUAL - NV4500BR/BE
SHIFT MECHANISM - NV4500 (Continued)

SHIFT COVER - NV4500
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission shift cover.
(5) Remove the shift tower and isolator plate from
the transmission shift cover.
INSTALLATION
(1) Clean the mating surfaces of shift tower, isola-
tor plate and shift cover with suitable wax and
grease remover.(2) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(3) Install the isolator plate onto the shift cover,
metal side down.
(4) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(5) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(6) Install bolts to hold the shift tower to the iso-
lator plate and the shift cover. Tighten the shift
tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(7) Install shift lever extension, shift boot and
bezel.
BR/BEMANUAL - NV4500 21 - 45