DODGE RAM 2003 Service Repair Manual

(42) Set transmission case upright (Fig. 109).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 110). 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.DRIVE GEAR AND RETAINER
(1) Install bearing on drive gear with Installer
6448 (Fig. 111).
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear
rearward until mainshaft hub is seated in pilot bear-
ing.
(4) Install bearing cup in front retainer with Han-
dle C-4171 and Installer C-4308 (Fig. 112).
Fig. 109 MAINSHAFT AND GEARTRAIN IN CASE
1 - MAINSHAFT AND GEARTRAIN
2 - FOURTH SPEED CLUTCH GEAR
Fig. 110 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 111 FRONT BEARING ON DRIVE GEAR
1 - INSTALLER
2 - BEARING
3 - DRIVE GEAR
Fig. 112 FRONT BEARING CUP IN RETAINER
1 - INSTALLER
2 - HANDLE
3 - WOOD BLOCKS
4 - RETAINER
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MANUAL TRANSMISSION - NV4500 (Continued)

(5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 113). Use one or two wood
blocks to support retainer as shown. Lubricate seal
lip with petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover.
(7) Apply Mopar Silicone Sealer or equivalent to
flange surface of front bearing retainer (Fig. 114).
(8) Install front bearing retainer over drive gear
and start it into case.
(9) Start front bearing retainer in gear case. Verify
retainer lube channel is at the top-center(12
O'clock)position (Fig. 114).(10) Align front bearing retainer bolt holes and tap
retainer into place with plastic mallet. Installnew
retainer bolts and tighten to 30 N´m (22 ft. lbs.) (Fig.
115).
NOTE: Never reuse the old bolts.
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. 116).
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. 116).
(11) Apply Mopar Lock N' Seal or equivalent to
bearing plate bolt threads. Install and tighten bolts
to 23 N´m (200 in. lbs.).
Fig. 113 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - RETAINER
3 - WOOD BLOCK
Fig. 114 LOCATION OF FRONT RETAINER LUBE
CHANNEL
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 115 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
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MANUAL TRANSMISSION - NV4500 (Continued)

(12) Install mainshaft fifth gear with Installer
6446 (Fig. 117). Gear is seated when it contacts rear
bearing.
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) Install thrust washer pin in countershaft (Fig.
118).
(2) Install thrust washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 119).
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. 120).
Fig. 116 REAR BEARING PLATE
1 - BEARING PLATE OIL HOLE (AT TOP)
2 - MAINSHAFT REAR BEARING PLATE
Fig. 117 MAINSHAFT FIFTH GEAR
1 - MAINSHAFT FIFTH GEAR
2 - INSTALLER
Fig. 118 FIFTH GEAR THRUST WASHER PIN
1 - THRUST WASHER PIN
2 - COUNTERSHAFT
Fig. 119 FIFTH GEAR THRUST WASHER
1 - PIN
2 - THRUST WASHER
Fig. 120 COUNTERSHAFT FIFTH GEAR BEARING
1 - COUNTERSHAFT
2 - FIFTH GEAR NEEDLE BEARING
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MANUAL TRANSMISSION - NV4500 (Continued)

(4) Install synchro sleeve on hub of countershaft
fifth gear with tapered side of sleeve facing front and
the flat side facing rear (Fig. 121).
(5) Install shift fork in synchro sleeve (Fig. 122).
(6) Install assembled fifth gear, synchro sleeve and
shift fork (Fig. 123). Align fork with shift lug rail and
align gear with bearings and countershaft. Start
components onto shaft and rail, then tap gear and
fork into place with plastic or rawhide mallet.
(7) Install fifth gear synchro struts and springs
(Fig. 124).
Fig. 121 SYNCHRO SLEEVE ON COUNTERSHAFT
FIFTH
1 - GEAR HUB
2 - SYNCHRO SLEEVE
3 - COUNTERSHAFT FIFTH GEAR
Fig. 122 FIFTH GEAR SHIFT FORK IN SYNCHRO
SLEEVE
1 - SYNCHRO SLEEVE
2 - SHIFT FORK
Fig. 123 COUNTERSHAFT FIFTH GEAR, SHIFT
FORK AND SYNCHRO SLEEVE
1 - SHIFT FORK AND SLEEVE
2 - FIFTH GEAR HUB
3 - SHIFT FORK ROLL PINS
Fig. 124 FIFTH GEAR SYNCHRO STRUTS AND
SPRINGS
1 - FIFTH GEAR HUB
2 - SYNCHRO SPRING (3)
3 - SYNCHRO STRUT (3)
DRMANUAL TRANSMISSION - NV4500 21 - 75
MANUAL TRANSMISSION - NV4500 (Continued)

(8) Assemble and install fifth synchro clutch gear
and stop ring in fifth gear hub (Fig. 125). Verify
parts are seated in fifth gear hub.
(9) Install clutch gear snap ring (Fig. 126).
(10) Align roll pin holes in shift fork with notches
in shift lug rail. Then install roll pins from top side
of fork (Fig. 123).
NOTE: Roll pins only fit one way due to small
shoulder at one end of each pin.
FIFTH GEAR NUT
(1) Install belleville washer onto the mainshaft.
(2) Install fifth gear nut over the mainshaft.
(3) Tighten the clamp bolt until the gap in the
clamp nut assembly is closed.
(4) Back the clamp bolt off one full turn.(5) Place 10-15 drops of Loctite 272 onto the main-
shaft threads where the fifth gear nut will be
engaged.
(6) Install fifth gear nut on mainshaft (Fig. 127).
(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
Wrench 6743, long handle ratchet, breaker bar and
applicable socket wrench (Fig. 128).
(9) Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
Fig. 125 FIFTH SYNCHRO CLUTCH GEAR AND
STOP RING
1 - STOP RING
2 - CLUTCH GEAR
Fig. 126 FIFTH SYNCHRO CLUTCH SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
Fig. 127 FIFTH GEAR NUT
1 - FIFTH GEAR
2 - FIFTH GEAR NUT
Fig. 128 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SOCKET
21 - 76 MANUAL TRANSMISSION - NV4500DR
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)

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Switch, Back-up Lamp 22-34 16-25 -
Countershaft Bearing Plate Bolts 19-26 14-19 170-230
Fifth Gear Nut 366-380 270-280 -
Fifth Gear Nut Clamp Bolt 13.5 10 -
Drain and Fill Plug 34-47 25-35 -
Front Bearing Retainer Bolts 27-34 20-25 235-305
Mainshaft Bearing Plate Bolts 19-26 14-19 170-230
PTO Cover Bolts 27-54 20-40 -
Extension/Adapter Housing Bolts 41-68 30-50 -
Shift Mechanism Cover Bolts 27-31 20-23 -
Transmission Bolts 108 80 -
SPECIAL TOOLS
REMOVER C-3985-B
BUSHING REMOVER 6957
REMOVER BUSHING 8155
INSTALLER BUSHING 6951
INSTALLER BUSHING 8156
HANDLE C-4171
DRMANUAL TRANSMISSION - NV4500 21 - 79
MANUAL TRANSMISSION - NV4500 (Continued)

INSTALLER SEAL C-3972-A
INSTALLER SEAL 8154
INSTALLER SEAL C-3860-A
WRENCH 6443
WRENCH 6743
SOCKET 6441
SOCKET 6442
SOCKET 6993
SOCKET 6984
PULLER 6444
21 - 80 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

JAWS 6459
JAWS 6820
JAWS & INSERT 6453
JAWS 6447
JAWS 6449
JAWS 6451
REMOVER 6454
INSTALLER 6061
INSTALLER C-4340
DRMANUAL TRANSMISSION - NV4500 21 - 81
MANUAL TRANSMISSION - NV4500 (Continued)