light DODGE RAM 2003 Service Repair Manual

(5) Remove shift tower and isolator plate from
transmission shift cover.
(6) Raise and support vehicle.
(7) Remove skid plate, if equipped.
(8) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(9) Remove exhaust system Y-pipe.
(10) Disconnect speed sensor and backup light
switch connectors.
(11) Support engine with safety stand and a wood
block.
(12) If transmission is to be disassembled, remove
drain bolt at bottom of PTO cover and drain lubri-
cant (Fig. 3).
TWO WHEEL DRIVE
(1) Remove bolts attaching transmission to rear
crossmember mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember bolts and pry out
crossmenber.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
NOTE: The hydraulic linkage has a quick connect at
the slave cylinder. This fitting should not be discon-
nected.
(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. 4).(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(9) Remove rear crossmember bolts and pry out
crossmenber.
(10) Remove clutch slave cylinder splash shield, if
equipped.
(11) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
NOTE: The hydraulic linkage has a quick connect at
the slave cylinder. This fitting should not be discon-
nected.
(12) Remove transmission to clutch housing bolts.
(13) Slide transmission and jack rearward until
input shaft clears clutch housing.
(14) Lower transmission jack and remove trans-
mission from under vehicle.
DISASSEMBLY
SHIFT MECHANISM
(1) Remove bolts holding shift tower to shift mech-
anism cover and remove tower.
Fig. 3 FILL AND DRAIN PLUGS
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
Fig. 4 TRANSFER CASE SHIFTER-TYPICAL
1 - TRANSMISSION
2 - TRANSFER CASE SHIFT MECHANISM
21 - 44 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 21).
CAUTION: Do not reuse retainer bolts.
(2) Lightly tap retainer back and forth with plastic
mallet 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. 22) collaps-
ing one side of seal then prying it out.(4) Remove front retainer bearing cup with Puller
6444. Assemble Puller Flange 6444-1 and Puller Rods
6444-4 (Fig. 23). Insert Jaws 6453-1 in puller flange.
Narrow lip of puller jaws will go under bearing cup.
(5) Install Disc C-4487-1 into bearing retainer for
Insert 6453-2 to rest upon.
(6) Install assembled tools in front retainer (Fig.
24) with puller jaws seated under bearing cup. Place
Insert 6453-2 in center of puller jaws, to hold puller
jaws in place.
Fig. 21 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
Fig. 22 BEARING RETAINER SEAL
1 - SEAL
2 - FRONT BEARING RETAINER
Fig. 23 PULLER RODS, FLANGE AND JAWS
1 - RODS
2 - FLANGE
3-JAWS
Fig. 24 INSERT AND RETAINER
1 - INSERT
2 - FRONT RETAINER
3-JAWS
DRMANUAL TRANSMISSION - NV4500 21 - 49
MANUAL TRANSMISSION - NV4500 (Continued)

(7) Install Puller 6444 on puller rods (Fig. 25) and
install retaining nuts on puller rods. Tighten puller
bolt to draw bearing cup out of retainer.
DRIVE GEAR
(1) Remove drive gear (Fig. 26).
(2) Remove pilot bearing from drive gear (Fig. 27).
(3) Remove tapered bearing from drive gear with
Puller Flange 6444-1 and Puller Rods 6444-6 (Fig.
28).
(4) Position first Jaw 6447 on bearing. Slide
assembled puller flange and rod tools onto input
shaft. Then seat flange in notch of puller jaw.
(5) Position second Jaw 6447 on gear and in notch
of puller flange. Slide Collar 6444-8 over puller jaws
to hold them in place.
(6) Install Puller 6444 on puller rods then install
retaining nuts. Tighten puller bolt to remove bearing
cone from drive gear.
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. 29).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 30).
(4) Roll gear case onto left side.(5) Remove mainshaft assembly (Fig. 31) by lifting
front end of mainshaft slightly. Then grasp mainshaft
rear splines and turn spline end of mainshaft coun-
terclockwise to rotate shaft and geartrain out of case.
Tilt mainshaft outward and removed from case.
NOTE: Handling mainshaft carefully because gears
are lose on the mainshaft.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
32).
Fig. 25 BEARING CUP PULLER ASSEMBLY
1 - WRENCH
2 - INSERT
3 - FRONT RETAINER
4 - PULLER
5 - WRENCH
Fig. 26 DRIVE GEAR
1 - MAINSHAFT
2 - DRIVE GEAR
Fig. 27 PILOT BEARING
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
21 - 50 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 41).
(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 42).
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 43). A small pin punch can be mod-
ified by putting a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 43).
(4) Remove shift lug rail.MAINSHAFT
NOTE: Gear and synchro components can be
installed backwards. Paint or scribe gear and syn-
chro components for installation reference. Then
stack geartrain parts in order of removal.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Place 3-4 gear in a press with support under
3rd gear and Remove 3-4 synchro hub, third gear
stop ring and third gear as an assembly (Fig. 44).
(3) Remove third gear bearing from mainshaft
(Fig. 45).
(4) Remove third gear bearing spacer (Fig. 46).
(5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 46).
(6) Remove second gear thrust washer (Fig. 47).
Note washer notch for locating pin.
Fig. 41 COUNTERSHAFT FRONT BEARING CAP
1 - HAMMER
2 - BEARING CAP
Fig. 42 COUNTERSHAFT FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 43 SHIFT LUG ROLL PIN
1 - PUNCH
2 - 30É BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
21 - 54 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(10) Install assembled second gear clutch cone and
rings on mainshaft and in 1-2 synchro hub (Fig. 88).
(11) Install snap ring that secures second gear
clutch cone on mainshaft (Fig. 89). Use narrow blade
screwdriver to work snap ring into hub groove as
shown. Verify snap ring is seated in mainshaft
groove.
NOTE: If snap ring will not fit in groove, clutch cone
is slightly misaligned.(12) Install second gear bearing on mainshaft (Fig.
90).
(13) Install second gear on mainshaft and bearing.
Rotate gear until tabs of second gear clutch ring are
seated in tab slots in gear (Fig. 91).
Fig. 88 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - CLUTCH CONE
2 - STOP RING
3 - CLUTCH RING
Fig. 89 SECOND GEAR CLUTCH CONE SNAP RING
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
4 - SECOND GEAR CLUTCH CONE
Fig. 90 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
Fig. 91 SECOND GEAR
1 - SECOND GEAR
2 - CLUTCH RING TABS
3 - TAB SLOTS (IN GEAR)
DRMANUAL TRANSMISSION - NV4500 21 - 67
MANUAL TRANSMISSION - NV4500 (Continued)

(e) Install second and third struts in same man-
ner as described in step (d).
(f) Work sleeve upward on hub until struts are
centered and seated in sleeve. Sleeve should be in
neutral position after seating struts.
(34) Install reverse gear and synchro assembly on
mainshaft (Fig. 104). Rotate assembly until stop ring
lugs engage in hub slots and gear drops into seated
position.
(35) Install reverse gear thrust washer (Fig. 105).
(36) Install rear bearing on mainshaft with
Installer 6446. Seat bearing on output shaft and
against thrust washer (Fig. 106).
(37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 107).
(38) Install fourth gear clutch gear in stop ring
(Fig. 108).
(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.
Fig. 104 REVERSE GEAR
1 - REVERSE GEAR AND SYNCHRO ASSEMBLY
Fig. 105 REVERSE GEAR THRUST WASHER
1 - THRUST WASHER
2 - REVERSE GEAR
Fig. 106 MAINSHAFT REAR BEARING
1 - INSTALLER
2 - MAINSHAFT REAR BEARING
Fig. 107 FOURTH GEAR STOP RING
1 - 3-4 SYNCHRO SLEEVE
2 - FOURTH SPEED STOP RING
Fig. 108 FOURTH GEAR CLUTCH GEAR
1 - FOURTH SPEED CLUTCH GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 71
MANUAL TRANSMISSION - NV4500 (Continued)

(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. 129).
(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.).
SHIFT MECHANISM
(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. 130) 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.
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.
Fig. 129 INSTALLING EXTENSION/ADAPTER
HOUSING
1 - GEAR CASE
2 - EXTENSION HOUSING
Fig. 130 SHIFT FORK PAD
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
DRMANUAL TRANSMISSION - NV4500 21 - 77
MANUAL TRANSMISSION - NV4500 (Continued)

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 transmission bolts and tighten 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 transfer case nuts and tighten to:
²If 3/8 studs 41-47 N´m (30-35 ft. lbs.).
²If 5/16 studs 30-41 N´m (22-30 ft. lbs.).
(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.
(18) 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.).
(19) Install the shift lever extension onto the shift
tower and lever assembly.
(20) Install shift lever boot and bezel.
(21) Connect battery negative cable.
21 - 78 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

ADAPTER HOUSING SEAL
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. 131).
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
REMOVAL
(1) Mark the propeller shaft and yoke for installa-
tion reference.
(2) Remove the propeller shaft.(3) Remove extension housing seal (Fig. 132) using
Remover C-3985-B.
(4) On heavy duty 4X2 vehicles, remove extension
housing seal with a pry tool or a slide hammer
mounted screw.
(5) On light duty transmissions, remove the exten-
sion housing bushing with Remover 6957.
(6) On heavy duty transmissions, remove the
extension housing bushing with Remover 8155.
INSTALLATION
(1) Install housing bushing with Handle C-4171
(Fig. 133) and Installer.
²Light Duty - Installer 6951
²Heavy Duty - Installer 8161
Fig. 131 Adapter Housing (4±Wheel Drive Models)
1 - ADAPTER HOUSING
2 - SEAL
Fig. 132 EXTENSION HOUSING AND SEAL (4X2)
1 - EXTENSION HOUSING
2 - SEAL
Fig. 133 Extension Housing Bushing
1 - HANDLE
2 - INSTALLER
3 - EXTENSION HOUSING
DRMANUAL TRANSMISSION - NV4500 21 - 83

(2) Install housing seal with Handle C-4171 (Fig.
134) and Installer.
²Light Duty - Installer C-3972-A
²Heavy Duty - Installer 8154
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
SHIFT MECHANISM
REMOVAL
(1) Remove transmission from vehicle.
(2) Remove shift mechanism cover bolts (Fig. 135).(3) Pry up shift mechanism cover at slots provided
in cover (Fig. 136).
(4) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 137).
(5) Raise front of shift mechanism cover and lift
cover up and off gear case (Fig. 137).
Fig. 134 Pinion Seal
1 - HANDLE
2 - INSTALLER
Fig. 135 SHIFT MECHANISM BOLTS
1 - SHIFT MECHANISM COVER
2 - BOLTS
Fig. 136 LOOSEN SHIFT MECHANISM
1 - SHIFT MECHANISM COVER SLOT
2-PRYTOOL
Fig. 137 SHIFT MECHANISM COVER
1 - SHIFT MECHANISM COVER
2 - ALIGNMENT DOWELS
21 - 84 MANUAL TRANSMISSION - NV4500DR
EXTENSION HOUSING SEAL (Continued)