Transmission DODGE RAM 2003 Service Repair Manual

(6) Install assembled output shaft and geartrain in
input shaft (Fig. 85). Carefully rotate output shaft
until the 3-4 synchro ring seats in synchro hub and
sleeve.
(7) Install Adapter 6747-2A on front bearing hub of
countershaft, if not previously done. The shoulder
goes toward the countershaft.
(8) Slide countershaft (and adapter) into fixture
slot. Verify countershaft and output shaft gears are
fully meshed with the mainshaft gears before pro-
ceeding (Fig. 86).
(9) Check alignment of countershaft and output
shaft gear teeth. Gears may not align perfectly a dif-
ference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.)
will probably exist. This will not interfere with
assembly. If difference is greater than this, the coun-
tershaft adapter tool is probably upside down.
(10) Position reverse idler in support cup of fixture
(Fig. 87). Verify idler gear is properly meshed and
aligned with shaft gear teeth and that bolt holes are
facing out from the geartrain. Adjust pedestal up or
down if necessary and verify short end of idler shaft
is facing up as shown.
Fig. 86 COUNTERSHAFT ON FIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig. 87 REVERSE IDLER ASSEMBLY ON FIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - PEDESTAL
Fig. 85 OUTPUT SHAFT, GEARTRAIN & INPUT
SHAFT
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE 6747
21 - 28 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(11) On 2-wheel drive transmission, thread one
Alignment Pin 8120 in center or passenger side hole
of output shaft bearing retainer. Then position
retainer on fifth gear as shown (Fig. 88).
(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
89). Arm of fifth-reverse fork goes through slot in 1-2
fork.
(13) Install assembled shift forks in synchro
sleeves and verify forks are seated in sleeves (Fig.
90).
REAR HOUSING - 2WD
NOTE: Transmission shift components must be in
Neutral position to prevent damaging the synchro
and shift components when installing the housings.
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 91).
Fig. 88 ALIGN OUTPUT SHAFT BEARING RETAINER
1 - ALIGNMENT PIN
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 89 1-2 & FIFTH-REVERSE SHIFT FORKS
1 - 1-2 FORK
2 - 1-2 FORK ARM
3 - FIFTH-REVERSE FORK
Fig. 90 SHIFT FORKS IN SYNCHRO
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
Fig. 91 REAR HOUSING DOWELS
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
DRMANUAL TRANSMISSION - NV3500 21 - 29
MANUAL TRANSMISSION - NV3500 (Continued)

(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 92).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(4) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 93).
(6) Reach into countershaft rear bearing with fin-
ger and push each bearing roller outward against the
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(7) Install rear housing onto geartrain (Fig. 94)
and verify bearing retainer pilot stud is in correct
bolt hole in housing. Verify countershaft and output
shaft bearings are aligned in housing and on counter-
shaft.
NOTE: It may be necessary to lift upward on coun-
tershaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.(8) Seat rear housing on output shaft rear bearing
and countershaft by tapping the housing with a plas-
tic mallet.
Fig. 92 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY
Fig. 93 COUNTERSHAFT BEARING
1 - SHIFT SHAFT BUSHING/BEARING
2 - COUNTERSHAFT REAR BEARING
Fig. 94 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
21 - 30 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(9) Apply Mopar Gasket Maker or equivalent to
housing bolt threads, bolt shanks and under bolt
heads (Fig. 95).
(10) Start first two bolts in retainer (Fig. 96). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 96).
(12) Tighten retainer bolts to 30-35 N´m (22-26 ft.
lbs.).ADAPTER HOUSING - 4WD
NOTE: Transmission shift components must be in
Neutral to prevents damaging to the synchro and
shift components when installing the housings.
(1) Install rear bearing in adapter housing. Use
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 97).
(3) Apply Mopar Gasket Maker or equivalent to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 95).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 93).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 93).
Fig. 95 HOUSING BOLTS
1 - GASKET MAKER
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 96 Alitgnment Pin And Retainer Bolts
1 - BEARING RETAINER BOLT
2 - ALIGNMENT PIN
Fig. 97 ADAPTER HOUSING
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 31
MANUAL TRANSMISSION - NV3500 (Continued)

(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 98).
(10) Lubricate lip of new rear seal (Fig. 99) with
Mopar Door Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 99).SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify all synchro sleeves are in Neutral posi-
tion (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position to prevent damaging the housings,
shift forks and gears while installing the housings.
(2) Install 3-4 shift fork in synchro sleeve (Fig.
100). Verify groove in fork arm is aligned with
grooves in 1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
101).
Fig. 98 REAR BEARING SNAP RING
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 99 ADAPTER HOUSING REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
Fig. 100 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 101 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
21 - 32 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(4) Assemble shift shaft shift lever and bushing
(Fig. 102). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 103).
(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
104).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 105).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-mission will have to be disassembled again to cor-
rect shaft alignment.
(9) Select correctnewroll pin for shift shaft lever
(Fig. 106). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
Fig. 102 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 103 SHIFT SHAFT LEVER AND BUSHING
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 104 SHAFT LEVER OPENING
1 - SHIFT SHAFT
Fig. 105 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 106 ROLL PIN IDENTIFICATION
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
DRMANUAL TRANSMISSION - NV3500 21 - 33
MANUAL TRANSMISSION - NV3500 (Continued)

(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 107).
(11) Seat shaft lever roll pin with pin punch (Fig.
108).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 108).(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 109).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket after installation
(Fig. 110).
Fig. 107 SHIFT SHAFT ROLL PIN
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
Fig. 108 SHIFT SHAFT/LEVER ROLL PIN
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 109 SHIFT SOCKET ROLL PIN
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 110 SEAT SHIFT SOCKET
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
21 - 34 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(15) Verify that notches in shift fork arms are
aligned (Fig. 111). Realign arms if necessary.
(16) Rotate shift lever and bushing downward to
expose detent bore in the lever.
(17) Install detent spring then the ball into the
detent bore (Fig. 112) and hold the ball in the lever.
Then rotate the lever upward into the fork arm
notches.
NOTE: Verify detent ball is seated in the fork arms
before proceeding.
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) If previously removed, install input shaft bear-
ing in front housing bore (Fig. 113). Install snap ringand use plastic mallet to seat bearing. Bearing goes
in from front side of housing only.
(2) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 113). Large diameter side of
bearing cage goes toward countershaft (Fig. 114).
Small diameter side goes toward bearing race in
housing.
(3) Reach into countershaft front bearing with fin-
ger and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
Fig. 111 SHIFT LEVER POSITION
1 - SHIFT FORK ARMS
2 - DETENT BORE
Fig. 112 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
Fig. 113 INPUT SHAFT & COUNTERSHAFT
BEARING
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 35
MANUAL TRANSMISSION - NV3500 (Continued)

(5) Apply 1/8 in. wide bead of Mopar Gasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 115).
(6) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.
CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(9) Place transmission in horizontal position.
(10) Apply Mopar Gasket Maker or equivalent to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 116).
(11) Install and start housing attaching bolts by
hand (Fig. 116). Then tighten bolts to 34 N´m (25 ft.
lbs.).(12) Install shift shaft bushing lock bolt (Fig. 117).
Apply Mopar Gasket Maker or equivalent to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubricate then install shift shaft detent
plunger in housing bore. Lubricate plunger with
semi-synthetic/synthetic grease. Verify plunger is
fully seated in detent notch in shift shaft.
(14) Install detent spring inside plunger.
(15) Install detent plug in end of Installer 8123.
Position plug on detent spring and compress spring
until detent plug pilots in detent plunger bore. Drive
detent plug into transmission case until plug seats.
Fig. 115 SEAL HOUSINGS
1 - HOUSING FLANGE SURFACE
2 -GASKET MAKER
Fig. 116 HOUSING BOLTS
1 - HOUSING BOLTS
Fig. 117 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
21 - 36 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(16) Install backup light switch (Fig. 118).
(17) Install input shaft snap ring (Fig. 119).
(18) Installnewoil seal in front bearing retainer
with Installer 6448 (Fig. 120).(19) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
121).
(20) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
122). Verify bolt holes are aligned before seating
retainer.
CAUTION: Be sure sealer does not get into the oil
feed hole in the transmission case or bearing
retainer.
Fig. 118 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 119 SHAFT SNAP RING - TYPICAL
1 - INPUT SHAFT SNAP RING
Fig. 120 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - FRONT BEARING RETAINER
Fig. 121 SEAL BEARING RETAINER - TYPICAL
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
Fig. 122 INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
3 - BEARING RETAINER
DRMANUAL TRANSMISSION - NV3500 21 - 37
MANUAL TRANSMISSION - NV3500 (Continued)