1998 DODGE RAM 1500 Locks

(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear.
(2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 28
N´m (250 in. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
STEERING WHEEL
REMOVAL
(1) Disable and remove the driver's side air-
bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 61 N´m (45 ft. lbs.).
(3) Install the driver's side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DRCOLUMN 19 - 15
LOWER STEERING COUPLING (Continued)

TILT LEVER KNOB RELEASE
REMOVAL
(1) Remove the tilt lever handle.
(2) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(3) Remove the lower shroud.
NOTE: Use special care not to pry on the clock-
spring electrical connector when removing or
installing the mounting screw located next to the
clockspring.
(4) Remove the two mounting screws from the tilt
lever knob release bracket (Fig. 22).
(5) Disconnect the electrical harness plastic
mounting tab from the the bracket (Fig. 22).
(6) Unsnap the cable from the bracket (Fig. 23).
(7) Remove the end of the cable from the tilt lever
knob release bracket (Fig. 24).
INSTALLATION
(1) Route the cable into the tilt lever release knob
bracket (Fig. 24).
(2) Snap the cable end into the bracket (Fig. 23).
NOTE: Use special care not to pry on the clock-
spring electrical connector when removing or
installing the mounting screw located next to the
clockspring.
NOTE: New screws should be used when installing
the tilt lever release knob bracket to the column.(3) Install the tilt lever release knob bracket to the
column and install the two new mounting screws
(Fig. 22) Tighten the two new screws to 4.5 N´m (40
in. lbs.).
(4) Install the electrical harness plastic mounting
tab to the bracket (Fig. 22).
(5) Install the lower shroud.
(6) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(7) Install the tilt lever handle.
Fig. 22 TILT LEVER KNOB RELEASE BRACKET
1 - TILT LEVER RELEASE KNOB BRACKET
2 - ELECTRICAL HARNESS TAB
3 - MOUNTING SCREWS (2)
Fig. 23 CABLE UNSNAPPED
1 - TILT LEVER RLEASE KNOB BRACKET
2 - TILT LEVER CABLE REMOVAL/INSTALL
Fig. 24 END OF CABLE TO THE TILT LEVER
RELEASE KNOB
1 - TILT LEVER RELEASE KNOB BRACKET
2 - END OF CABLE REMOVAL/INSTALL
19 - 16 COLUMNDR

OUTPUT SHAFT
NOTE: Lubricate shaft, gears, bearings and
immerse each synchro ring with recommended
lubricant during assembly. Petroleum jelly can be
used to hold parts in place.
(1) Install reverse gear needle bearing up against
shoulder on output shaft (Fig. 50).
(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.
Fig. 50 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
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
21 - 18 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(5) Installnewfifth-reverse hub snap ring (Fig.
54). Verify snap ring is seated in the groove.
(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).
Fig. 54 FIFTH/REVERSE SYNCHRO HUB SNAP RING
1 - FIFTH-REVERSE SYNCHRO ASSEMBLY
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
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
DRMANUAL TRANSMISSION - NV3500 21 - 19
MANUAL TRANSMISSION - NV3500 (Continued)

(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.
(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.
Fig. 58 FIRST GEAR
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - COLLAR
4 - PRESS BLOCKS
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
21 - 20 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(2) Install first gear clutch cone on mainshaft 1-2
synchro hub with recessed side of cone facing front
(Fig. 79). Verify cone is seated against snap ring on
hub.
(3) Install snap ring on mainshaft 1-2 synchro hub
to secure clutch cone (Fig. 80). Verify snap ring is
seated in hub groove and against clutch cone.
(4) Support mainshaft in upright position to install
remaining gears, snap rings and synchro compo-
nents. Shaft can be supported in gear case or hole
can be cut in workbench to support shaft.
(5) If 1-2 synchro hub and sleeve were disassem-
bled for service, reassemble hub, sleeve, struts and
springs as follows:(a) Align and install sleeve on hub. Rotate sleeve
until it slides onto hub. Sleeve only fits one way
and will easily slide onto hub when long slot in
sleeve, aligns with long shoulder on hub (Fig. 81).
(b)
Place wood blocks under hub that will raise hub
about 3.5 cm (1.375 in.) above surface of workbench.
Then allow sleeve to drop down on hub (Fig. 82).
(c)Install springs and struts in hub (Fig. 82). Use
lots of petroleum jelly to hold them in place. Then
compress struts with your fingers and move sleeve
upward until struts are started in sleeve. Verify that
struts are engaged in sleeve before proceeding.
(d) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated
and springs are not displaced during assembly.
Fig. 79 FIRST GEAR CLUTCH CONE
1 - MAINSHAFT 1-2 SYNCHRO HUB
2 - FIRST GEAR CLUTCH CONE
Fig. 80 FIRST GEAR CLUTCH CONE SNAP RING
1 - FIRST GEAR CLUTCH CONE
2 - MAINSHAFT 1-2 SYNCHRO HUB
3 - CLUTCH CONE SNAP RING
Fig. 81 1-2 SYNCHRO SLEEVE ON HUB
1 - ALIGN WIDE SLOT IN SLEEVE WITH WIDE SPLINE OF HUB
2 - 1-2 SLEEVE AND HUB
Fig. 82 1-2 SYNCHRO STRUTS AND SPRINGS
1 - WOOD BLOCKS
2 - HUB
3 - SLEEVE
4 - STRUTS AND SPRINGS (4 EACH)
DRMANUAL TRANSMISSION - NV4500 21 - 67
MANUAL TRANSMISSION - NV4500 (Continued)

(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.
(42) Set transmission case upright (Fig. 108).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 109). 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. 110).
(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. 111).
Fig. 108 MAINSHAFT AND GEARTRAIN IN CASE
1 - MAINSHAFT AND GEARTRAIN
2 - FOURTH SPEED CLUTCH GEAR
Fig. 109 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 110 FRONT BEARING ON DRIVE GEAR
1 - INSTALLER
2 - BEARING
3 - DRIVE GEAR
Fig. 111 FRONT BEARING CUP IN RETAINER
1 - INSTALLER
2 - HANDLE
3 - WOOD BLOCKS
4 - RETAINER
21 - 74 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 112). 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. 113).
(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. 113).(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.
114).
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. 115).
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. 115).
(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. 112 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - RETAINER
3 - WOOD BLOCK
Fig. 113 LOCATION OF FRONT RETAINER LUBE
CHANNEL
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 114 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
DRMANUAL TRANSMISSION - NV4500 21 - 75
MANUAL TRANSMISSION - NV4500 (Continued)