DODGE RAM 2003 Service Repair Manual

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................38
OPERATION...........................38
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 39
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....39
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............39
REMOVAL
REMOVAL - GAS......................40
REMOVAL - DIESEL...................40
INSTALLATION
INSTALLATION - GAS..................41
INSTALLATION - DIESEL................41
SPECIFICATIONS
TORQUE CHART......................41
FLUID
DESCRIPTION.........................42
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......42
FLUID COOLER
REMOVAL.............................42
INSTALLATION.........................42
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................43
REMOVAL - PRESSURE HOSE...........43
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................43INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................43
INSTALLATION - PRESSURE HOSE.......43
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............43
HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................43
REMOVAL - PRESSURE HOSE...........44
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................44
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................44
INSTALLATION - PRESSURE HOSE.......44
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............44
POWER STEERING PRESSURE SWITCH
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL - 3.7L, 4.7L & 5.7L..............45
INSTALLATION - 3.7L, 4.7L & 5.7L..........45
PULLEY
REMOVAL.............................45
INSTALLATION.........................46
RESERVOIR
REMOVAL.............................46
INSTALLATION.........................46
PUMP
DESCRIPTION
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump (Fig.
1). The power steering pumps are constant flow rate
and displacement, vane-type pumps.
19 - 38 PUMPDR

DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
Fig. 1 POWER STEERING PUMP
1 - 3.7L & 4.7L (6 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.7L,5.9L & 8.0L (7 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.9L DIESEL (8 GROOVE)
STEEL PULLEY
2 - PUMP ASSEMBLY
3 - RESERVOIR
4 - CAP
DRPUMP 19 - 39
PUMP (Continued)

(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
REMOVAL - GAS
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Disconnect the return hose. (Fig. 2)
(4) Disconnect the pressure hose. (Fig. 2)
(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes. (Fig. 2)
REMOVAL - DIESEL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Disconnect the return hose.
(4) Disconnect the pressure hose.
(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes.
(6) Loosen the pump bracket to the block.
(7) Remove the 6 intake plenum bolts (Fig. 3).
(8) loosen the inner cooler tube clamp at the
intake plenum and remove the intake plenum.
(9) Loosen the inner cooler tube clamp at the radi-
ator support side and remove the tube from the vehi-
cle.
(10) Remove the power steering pump from the top
of the engine compartment where the intake plenum
was (Fig. 3).
Fig. 2 POWER STEERING PUMP
1 - POWER STEERING PULLEY
2 - POWER STEERING RESERVOIR
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
Fig. 3 POWER STEERING PUMP ACCESS
1 - INTAKE PLENUM MOUNTING
2 - POWER STEERING PUMP
19 - 40 PUMPDR
PUMP (Continued)

INSTALLATION
INSTALLATION - GAS
(1) Align the pump with the mounting holes in the
left cylinder head.
(2) Install 3 pump mounting bolts through the pul-
ley access holes. Tighten the bolts to 28 N´m (21 ft.
lbs.).
(3) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N´m (27 ft. lbs.).
(4) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - DIESEL
(1) Set the power steering pump in place in the
engine compartment from the top (Fig. 3).
(2) Install the inner cooler tube.
(3) Tighten the inner cooler tube clamp at the
radiator support side.
(4) Install the 6 intake plenum bolts (Fig. 3).
(5) Tighten the inner cooler tube clamp at the
intake plenum.
(6) Install 3 pump mounting bolts through the pul-
ley access holes. Tighten the bolts to 28 N´m (21 ft.
lbs.).
(7) Tighten the pump bracket to the block.
(8) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N´m (27 ft. lbs.).
(9) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pressure
Switch10 Ð 80
Power Steering Line
Pressure Line32 23 Ð
Power Steering Line
Return Line71 52 Ð
Power Steering Line
Pressure Line To Pump37 27 Ð
Power Steering Pump
Mounting Bolts28 27 Ð
Power Steering Pump
Reservoir Bolts75Ð
Power Steering Pump
Bracket Bolts75Ð
DRPUMP 19 - 41
PUMP (Continued)

FLUID
DESCRIPTION
The recommended fluid for the power steering sys-
tem is MopartATF +4.
MopartATF+4, when new is red in color. The
ATF+4 is dyed red so it can be identified from other
fluids used in the vehicle such as engine oil or anti-
freeze. The red color is not permanent and is not an
indicator of fluid condition, As the vehicle is driven,
the ATF+4 will begin to look darker in color and may
eventually become brown.THIS IS NORMAL.
ATF+4 also has a unique odor that may change with
age. Consequently, odor and color cannot be used to
indicate the fluid condition or the need for a fluid
change.
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
The power steering fluid level can be viewed on the
dipstick attached to the filler cap. There are two
ranges listed on the dipstick, COLD and HOT. Before
opening power steering system, wipe the reservoir
filler cap free of dirt and debris. Remove the cap and
check the fluid level on its dipstick. When the fluid is
at normal ambient temperature, approximately 21ÉC
to 27ÉC (70ÉF to 80ÉF), the fluid level should read
between the minimum and maximum area of the cold
range. When the fluid is hot, fluid level is allowed to
read up to the highest end of the HOT range. Only
add fluid when the vehicle is cold.
Use only MopartATF+4Do not overfill the
power steering system.
FLUID COOLER
REMOVAL
(1) Drain and siphon the power steering fluid.
(2) Disconnect the return and supply hoses con-
nected to the power steering fluid cooler.(3) Remove the mounting bracket bolts securing
the fluid cooler to the brace. (Fig. 4)& (Fig. 5)
(4) Remove the fluid cooler from the vehicle.
INSTALLATION
(1) Install the fluid cooler to the vehicle.
(2) Install the mounting bracket bolts securing the
fluid cooler to the brace (Fig. 4)& (Fig. 5).
(3) Reclamp the return and supply hoses to the
power steering fluid cooler.
(4) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 4 V6 & V8 P/S FLUID COOLER
1 - POWER STEERING FLUID COOLER
2 - MOUNTING BOLTS
Fig. 5 V10 & DIESEL P/S FLUID COOLER
1 - RADIATOR
2 - POWER STEERING HOSES
3 - MOUNTING BOLTS
4 - P/S FLUID COOLER
19 - 42 PUMPDR

HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the return hose at the cooler.
(4) Disconnect the return hose at the gear (Fig. 6).
(5) Remove the return hose from the routing clamp
at the fan shroud and then remove from the vehicle.
REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the pressure hose at the pump.
(4) Disconnect the pressure hose at the gear (Fig.
6).
(5) Remove the pressure hose from the vehicle.
REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Disconnect the return hose at the reservoir.
(3) Raise and support the vehicle.
(4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler.
(6) Remove the hose from the vehicle.
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reconnect the return hose at the gear. Tighten
the hose to 71 N´m (52 ft. lbs.) (Fig. 6).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the gear.
Tighten the hose to 32 N´m (23 ft. lbs.) (Fig. 6).
(3) Reconnect the pressure hose at the pump.
Tighten the hose to 36 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
(5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the return hose at the cooler.
(4) Disconnect the return hose at the gear (Fig. 7).
(5) Remove the return hose from the routing clamp
at the fan shroud and then remove from the vehicle.
Fig. 6 HOSE CONNECTIONS
1 - RETURN HOSE
2 - PRESSURE HOSE
DRPUMP 19 - 43

REMOVAL - PRESSURE HOSE
(1) Drain and siphon the power steering system.
(2) Raise and support the vehicle.
(3) Disconnect the pressure hose at the pump.
(4) Disconnect the pressure hose at the gear (Fig.
8).
(5) Remove the pressure hose from the vehicle.
REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER
(1) Drain and siphon the power steering system.
(2) Disconnect the return hose at the reservoir.
(3) Raise and support the vehicle.
(4) Remove the return hose from the routing clamp
at the fan shroud.
(5) Disconnect the return hose at the cooler.
(6) Remove the hose from the vehicle.
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reconnect the return hose at the gear. Tighten
the hose to 71 N´m (52 ft. lbs.) (Fig. 7).
(4) Reattach the hose to the routing clip at the fan
shroud.
(5) Remove the support and lower the vehicle.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.
(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the gear.
Tighten the hose to 32 N´m (23 ft. lbs.) (Fig. 8).
(3) Reconnect the pressure hose at the pump.
Tighten the hose to 36 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
(5) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER
(1) Install the return hose to the vehicle.
(2) Reconnect the return hose at the cooler.
(3) Reattach the hose to the routing clip at the fan
shroud.
(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 7 POWER STEERING HOSES TO STEERING
GEAR
1 - HIGH PRESSURE HOSE
2 - RETURN HOSE
3 - STEERING GEAR
Fig. 8 HOSES INSTALLED
1 - LOWER COUPLING BOLT
2 - HIGH PRESSURE HOSE
3 - RETURN HOSE
4 - STEERING GEAR
5 - PITMAN ARM
19 - 44 PUMPDR
HOSES - LINK/COIL (Continued)

POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensing switch is used in the power
steering system. It is mounted on the high-pressure
steering hose (Fig. 9). This switch will be used with
both 3.7L, 4.7L and 5.7L engines. There is no pres-
sure switch used for the 5.9L pump.
OPERATION
The switch is used on the 3.7L V-6, 4.7L & 5.7L
V-8 engines.
The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
input is provided during periods of high steering
pump load and low engine rpm; such as during park-
ing maneuvers. The PCM increases the idle speed
through the Idle Air Control (IAC) motor. This is
done to prevent the engine from stalling under the
increased load.
When steering pump pressure exceeds 3275 kPa  
690 kPa (475 psi   100 psi), the Normally Closed
(NC) switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.
REMOVAL - 3.7L, 4.7L & 5.7L
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Disconnect electrical connector from power
steering pressure switch.
(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 3.7L, 4.7L & 5.7L
This switch is used only with the 3.7L V±6 and the
4.7L, 5.7L V-8 engines.
(1) Install power steering switch into power steer-
ing line.
(2) Tighten to 8±11 N´m (70±100 in. lbs.) torque.
(3) Connect electrical connector to switch.
(4) Check power steering fluid and add as neces-
sary.
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
PULLEY
REMOVAL
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Remove the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - REMOVAL).
(2) Remove the pulley from the pump with an
appropriate power steering pulley removal tool (Fig.
10).
Fig. 9 PRESSURE SWITCH
1 - POWER STEERING PULLEY
2 - POWER STEERING PUMP HOUSING
3 - POWER STEERING FLUID RESERVOIR
4 - RETURN HOSE
5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
Fig. 10 PULLEY REMOVAL
1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PULLEY REMOVAL TOOL
DRPUMP 19 - 45

INSTALLATION
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Replace the pulley if it's bent, cracked, or loose.
(2) Install the pulley on the pump with an appro-
priate power steering pulley installation tool (Fig. 11)
making sure it is flush with the end of the shaft.
Ensure the tool and pulley remain aligned with the
pump shaft.
(3) Install the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - INSTALLATION).
(4) Run engine until warm (5 min.) and note any
belt chirp. If chirp exists, move pulley outwardapproximately 0.5 mm (0.020 in.). If noise increases,
press on 1.0 mm (0.040 in.).Be careful that pulley
does not contact mounting bolts.
RESERVOIR
REMOVAL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
(3) Remove the power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove the reservoir mounting bolts.
(5) Remove the reservoir.
(6) Remove the rear bracket to the pump mounting
bolts.
INSTALLATION
(1) Install the reservoir bracket to the pump hous-
ing.Do not reuse the o-rings (install new
o-rings).Tighten bolts to 7 N´m (5 ft. lbs.).
NOTE: Ensure the reservoir is fully seated onto the
pump.
(2) Install the reservoir to the bracket/pump body.
(3) Install the reservoir mounting bolts. Tighten
bolts to 7 N´m (5 ft. lbs.).
(4) Install the power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(5) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(6) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 11 PULLEY INSTALLATION
1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL
19 - 46 PUMPDR
PULLEY (Continued)

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500..........1
MANUAL TRANSMISSION - NV4500..........42
MANUAL TRANSMISSION - NV5600..........87
AUTOMATIC TRANSMISSION - 46RE........129
AUTOMATIC TRANSMISSION - 48RE........310
AUTOMATIC TRANSMISSION - 45RFE/545RFE. . 488
TRANSFER CASE - NV241 GENII...........591
TRANSFER CASE - NV271................623
TRANSFER CASE - NV243................658
TRANSFER CASE - NV273................687
MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING................3
REMOVAL.............................3
DISASSEMBLY..........................4CLEANING............................15
INSPECTION..........................15
ASSEMBLY............................17
INSTALLATION.........................38
SPECIFICATIONS.......................39
SPECIAL TOOLS.......................40
MANUAL TRANSMISSION -
NV3500
DESCRIPTION
The transmission is a medium-duty 5-speed, con-
stant mesh fully synchronized manual transmission
with fifth gear overdrive range. The transmission is
available in two and four-wheel drive configurations.
The transmission gear case consists of two aluminum
housings (Fig. 1). The clutch housing 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
OPERATION
The manual transmission receives power through the
clutch assembly from the engine. The clutch disc issplined 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 transmission coun-
tershaft through the mesh of fourth speed gear on the
input shaft and the fourth countershaft 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 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 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.
DRTRANSMISSION AND TRANSFER CASE 21 - 1