Transmission DODGE RAM 2003 Service Repair Manual

(2) Install reverse gear over needle bearing (Fig.
51).
(3) Install brass synchro ring on reverse gear (Fig.
52).
(4) Start fifth-reverse synchro assembly on output
shaft splines by hand. Then seat synchro onto shaft
with shop press and Remover 6310-1 (Fig. 53).
CAUTION: One side of the hub has shoulders
around the hub bore, this side faces the front of the
shaft. One side of the sleeve is tapered the tapered
side faces the front of the shaft.
(5) Installnewfifth-reverse hub snap ring (Fig.
54). Verify snap ring is seated in the groove.
Fig. 51 REVERSE GEAR
1 - REVERSE GEAR
Fig. 52 REVERSE GEAR SYNCHRO
1 - REVERSE GEAR
2 - SYNCHRO RING
Fig. 53 FIFTH/REVERSE SYNCHRO ASSEMBLY
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - REMOVER 6310-1
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
Fig. 54 FIFTH/REVERSE SYNCHRO HUB SNAP RING
1 - FIFTH-REVERSE SYNCHRO ASSEMBLY
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
21 - 18 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(6) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 55).
(7) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 56).
Verify bearing is properly seated.(8) Install fifth gear on shaft and onto bearing
(Fig. 57).
(9) Invert output shaft and set the shaft in Collar
6310-1 so fifth gear is seated on the tool (Fig. 58).
(10) Install first gear bearing on output shaft (Fig.
58). Verify bearing is seated on shaft shoulder and is
properly joined.
Fig. 55 FIFTH GEAR SYNCHRO RING
1 - FIFTH-SPEED SYNCHRO RING
2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
Fig. 56 FIFTH GEAR BEARING
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 57 FIFTH GEAR
1 - FIFTH GEAR
2 - BEARING
Fig. 58 FIRST GEAR
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - COLLAR
4 - PRESS BLOCKS
DRMANUAL TRANSMISSION - NV3500 21 - 19
MANUAL TRANSMISSION - NV3500 (Continued)

(11) Install first gear on shaft and over bearing
(Fig. 59) with bearing synchro cone facing up.
(12) Install first gear synchro ring (Fig. 60).
(13) Start 1-2 synchro assembly on shaft by hand
(Fig. 61).
CAUTION: One side of the synchro sleeve is
marked First Gear Side, this side must face first
gear.
(14) Press 1-2 synchro onto output shaft using
suitable size pipe and shop press (Fig. 62).
CAUTION: Keep synchro ring and sleeve aligned as
the hub is being pressed onto the shaft. The syn-
chro ring can be cracked if it becomes misaligned.
Fig. 59 FIRST GEAR
1 - FIRST GEAR
2 - COLLAR
3 - BEARING
Fig. 60 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
2 - COLLAR
3 - FIRST GEAR
Fig. 61 STARTING 1-2 SYNCHRO
1 - 1-2 SYNCHRO ASSEMBLY
2 - COLLAR
3 - FIRST GEAR SIDE
Fig. 62 1-2 SYNCHRO ON OUTPUT SHAFT
1 - PIPE TOOL
2 - SYNCHRO RING
3 - COLLAR
4 - 1-2 SYNCHRO ASSEMBLY
5 - PRESS RAM
21 - 20 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(15) Install interm ring.
(16) Installnew1-2 synchro hub snap ring (Fig.
63). Verify snap ring is seated in shaft groove.
(17) Install second gear synchro ring in 1-2 syn-
chro hub and sleeve (Fig. 64). Verify synchro ring is
seated in sleeve.
(18) Install synchro friction cone and synchro cone
in synchro ring.(19) Install second gear needle bearing on shaft
(Fig. 65).
(20) Install second gear onto shaft and bearing
(Fig. 66). Verify second gear is seated on synchro
components.
Fig. 63 1-2 SYNCHRO HUB SNAP RING
1 - 1-2 SYNCHRO
2 - COLLAR
3 - SYNCHRO SNAP RING
Fig. 64 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - COLLAR
Fig. 65 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - COLLAR
Fig. 66 SECOND GEAR
1 - COLLAR
2 - 1-2 SYNCHRO ASSEMBLY
3 - BEARING
4 - SECOND GEAR
DRMANUAL TRANSMISSION - NV3500 21 - 21
MANUAL TRANSMISSION - NV3500 (Continued)

(21) Install two-piece thrust washer with halves
seated in the shaft groove and washer lugs seated in
shaft lug bores (Fig. 67). Verify i.d. grooves and
markings noted during removal are facing the correct
direction.
(22) Start retaining ring around two-piece thrust
washer (Fig. 68). Verify locating dimple is between
thrust washer halves.
(23) Seat thrust washer retaining ring with plastic
mallet (Fig. 69).
Fig. 67 TWO-PIECE THRUST WASHER
1 - WASHER GROOVE IN SHAFT
2 - LUG BORE
3 - THRUST WASHER LUGS
4 - LUG BORE
5 - LUG
6 - WASHER HALF
Fig. 68 RETAINING RING
1 - THRUST WASHER RETAINING RING
2 - THRUST WASHER HALVES
3 - SECOND GEAR
4 - LOCATING DIMPLE
Fig. 69 THRUST RETAINER
1 - PLASTIC MALLET
2 - THRUST WASHER RETAINING RING
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MANUAL TRANSMISSION - NV3500 (Continued)

(24) Install third gear needle bearing on shaft (Fig.
70).
(25) Install third gear on shaft and bearing (Fig.
71).(26) Install third speed synchro ring on third gear
(Fig. 72).
(27) Start 3-4 synchro hub on output shaft splines
by hand (Fig. 73).
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the sleeve has grooves in it, this side must
faces the front of the shaft.
Fig. 70 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 71 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 72 THIRD GEAR SYNCHRO RING
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 73 3-4 SYNCHRO HUB ON OUTPUT SHAFT
1 - GROOVED SIDE OF SLEEVE
2 - 3-4 SYNCHRO ASSEMBLY
DRMANUAL TRANSMISSION - NV3500 21 - 23
MANUAL TRANSMISSION - NV3500 (Continued)

(28) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to
output shaft as possible but not contacting the
shaft splines.
(29) Installnew3-4 synchro hub snap ring (Fig.
75). Verify snap ring is seated in groove.(30) Install output shaft bearing.
(31) Install output shaft bearing snap ring with
heavy duty snap ring pliers (Fig. 76). Verify snap
ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
(32) Verify position of synchro sleeves before pro-
ceeding (Fig. 77). Grooved side of 3-4 sleeve must
face forward. First gear side of 1-2 sleeve must face
first gear. Tapered side of fifth-reverse sleeve must
face forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube.
(2) Slide idler gear bearing on shaft (Fig. 78).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 78).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 78). Petroleum jelly can be used to
hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 79).
(6) Install snap ring in groove at rear of shaft (Fig.
79).
Fig. 74 3-4 SYNCHRO ON OUTPUT SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 75 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 76 OUTPUT SHAFT BEARING SNAP
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
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MANUAL TRANSMISSION - NV3500 (Continued)

Fig. 77 SYNCHRO SLEEVE LOCATIONS
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCHRO SLEEVE
8 - 3-4 SYNCHRO SLEEVE
Fig. 78 IDLER GEAR & BEARING
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFTFig. 79 IDLER GEAR REAR THRUST WASHER
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
DRMANUAL TRANSMISSION - NV3500 21 - 25
MANUAL TRANSMISSION - NV3500 (Continued)

(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
(8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 80).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 80). Verify snap
ring is seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/
BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
(2) If necessary, the shift shaft bushing can be
replaced as follows:
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.
(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case.
(3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case.
(4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive
the detent bushings through the outer case and
into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
the case.
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
Fig. 80 IDLER GEAR & SHAFT ASSEMBLY
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
21 - 26 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

GEARTRAIN ASSEMBLY
(1) Install Adapter 6747-1A on input shaft hub of
Fixture 6747 (Fig. 81). Then install Adapter 6747-2A
on front bearing hub of countershaft. Be sure the
shoulder is seated against the countershaft.
(2)
Install input shaft in fixture tool with Adapter Tool
6747-1A positioned under the shaft as shown (Fig. 82).
(3) Install pilot bearing in input shaft (Fig. 82).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.(4) Install fourth gear synchro ring on input shaft
(Fig. 83).
(5) Adjust height of idler gear pedestal on fixture
(Fig. 84). Start with a basic height of 18.4 cm (7-1/4
in.). Final adjustment can be made after gear is posi-
tioned on pedestal.
Fig. 81 FIXTURE FOR GEARTRAIN BUILD-UP
1 - ADAPTER 6747-2A
2 - CUP 8115
3 - ADAPTER 6747-1A
4 - FIXTURE 6747
Fig. 82 PILOT BEARING & INPUT SHAFT
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 83 FOURTH GEAR SYNCHRO
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 84 IDLER PEDESTAL BASE HEIGHT
1 - REVERSE IDLER PEDESTAL
DRMANUAL TRANSMISSION - NV3500 21 - 27
MANUAL TRANSMISSION - NV3500 (Continued)