1998 DODGE RAM 1500 transmission removal

IDENTIFICATION
The transmission has two identification tags
attached to the driver side upper clutch housing (Fig.
2). One tag provides the transmission part number.
The second tag provides sequencing and build date
information. The information on the tags are essen-
tial to correct parts ordering.
OPERATION
The driver selects a particular gear by moving the
shift lever to the desired gear position. As the shift
lever moves the selected shift rail, the shift fork
attached to that rail begins to move. The fork is posi-
tioned in a groove in the outer circumference of the
synchronizer sleeve. As the shift fork moves the syn-
chronizer 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 or the countershaft in
some cases, 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 friction cone and eventually will
slide over the teeth, locking the gear to the main-
shaft or countershaft through the synchronizer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incor-
rect lubricant level check. A correct lubricant level
check can only be made when the vehicle is level.
Also allow the lubricant to settle for a minute or sobefore checking. These recommendations will ensure
an accurate check and avoid an underfill or overfill
condition. Always check the lubricant level after any
addition of fluid to avoid an incorrect lubricant level
condition.
Leaks can occur at the mating surfaces of the gear
case, adaptor or extension housing, or from the front/
rear seals. A suspected leak could also be the result
of an overfill condition. Leaks at the rear of the
extension or adapter housing will be from the hous-
ing oil seals. Leaks at component mating surfaces
will probably be the result of inadequate sealer, gaps
in the sealer, incorrect bolt tightening or use of a
non-recommended sealer. A leak at the front of the
transmission will be from either the front bearing
retainer or retainer seal. Lubricant may be seen drip-
ping from the clutch housing after extended opera-
tion. If the leak is severe, it may also contaminate
the clutch disc causing the disc to slip, grab and or
chatter.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-
sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds. Severe highly audible transmission noise is
generally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant
will promote rapid wear of gears, synchros, shift
rails, forks and bearings. The overheating caused by
a lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Shift transmission into Neutral.
Fig. 2 IDENTIFICATION TAG LOCATION
1 - IDENTIFICATION TAGS
21 - 90 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

(6) Remove primary shift rail detent plunger (Fig.
9).
(7) Remove clutch housing bolts (10) (Fig. 10) from
inside the housing.(8) Remove shift rail blocker bolt (Fig. 11) from the
side of the transmission gear case.
EXTENSION/ADAPTER HOUSING
(1) Remove bolts holding the extension/adapter
housing onto the transmission gear case.
(2) Remove extension/adapter housing from the
transmission gear case with Puller 8244 (Fig. 12).
NOTE: It may be necessary to straighten the housing
during removal due to the tendency for the reverse
idler shaft to bind into one side of the housing.
Fig. 9 PRIMARY SHIFT RAIL DETENT PLUNGER
1 - DETENT PLUNGER
Fig. 10 CLUTCH HOUSING BOLTS
1 - BOLTS (10)
Fig. 11 SHIFT RAIL BLOCKER BOLT
1 - BLOCKER BOLT
Fig. 12 TRANSMISSION CASE PULLER
1 - PULLER
2 - EXTENSION/ADAPTER HOUSING
DRMANUAL TRANSMISSION - NV5600 21 - 93
MANUAL TRANSMISSION - NV5600 (Continued)

(2) Attach Fixture 8232 to the output shaft and
countershaft (Fig. 27).
(3) Attach an engine crane or equivalent to Fixture
8232 and raise the geartrain approximately 1/4 in.
from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
(5) Lower the geartrain back into the clutch hous-
ing.
(6) Install Holding Tool 8242 (Fig. 28) onto the 5-6
synchro and tighten the screw to hold the 5-6 syn-
chro together during the removal operation.
NOTE: Note the order of the shift fork arms at the
primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
(8) Remove shift rails from the rest of the
geartrain (Fig. 29).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
Fig. 27 FIXTURE/OUTPUT SHAFT
1 - OUTPUT SHAFT
2 - FIXTURE
Fig. 28 Remove Holding Tool
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 29 SHIFT RAILS
1 - 5-6 SHIFT RAIL
21 - 98 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

(3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 36).
(4) Remove input shaft bearing and oil guide from
the input shaft with Collar 6444-8, Jaws 8243, Puller
Rods 6444-6 and the remainder of Puller 6444 (Fig.
37).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be
installed backwards. Mark the gears, clutch gears,
synchro hubs, and sleeves for installation reference
during disassembly. Use paint or a scribe for mark-
ing purposes. Then stack the geartrain parts in
order of removal.
(1) Remove first gear from the output shaft.
(2) Remove first gear bearing from the output
shaft (Fig. 38).
Fig. 36 OUTPUT SHAFT POCKET BEARING RACE
1 - PULLER
2 - INPUT SHAFT
Fig. 37 INPUT SHAFT BEARING
1 - PULLER
2-JAWS
Fig. 38 FIRST GEAR BEARING
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING
DRMANUAL TRANSMISSION - NV5600 21 - 101
MANUAL TRANSMISSION - NV5600 (Continued)

ADAPTER HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Mark propeller shaft and yokes for installation
reference and remove shaft.
(3) Remove the transfer case.
(4) Remove the adapter housing seal with a pry
tool or slide hammer with a screw.
INSTALLATION
(1) Install adapter housing seal with Installer and
Handle C-4171.
(2) Install transfer case.
(3) Install propeller shaft with reference marks
aligned.
(4) Check fluid level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL
REMOVAL
(1) Mark propeller shaft and pinion yoke for
installation reference and remove the propeller shaft.
(2) Remove extension housing seal with a pry tool
or a slide hammer and screw.
(3) Remove extension housing bushing with
Remover 8155 (Fig. 97).
INSTALLATION
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171 (Fig. 98).
(2) Install extension housing seal with Installer
8154 and Handle C-4171 (Fig. 99).
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
Fig. 97 EXTENSION HOUSING BUSHING REMOVAL
1 - REMOVER
Fig. 98 Install Extension Housing Bushing
1 - HANDLE
2 - INSTALLER
3 - BUSHING
Fig. 99 EXTENSION HOUSING SEAL INSTALLER
1 - INSTALLER
2 - HANDLE
21 - 128 MANUAL TRANSMISSION - NV5600DR

SHIFT COVER
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(5) Remove the shift tower (Fig. 100) and isolator
plate (Fig. 101) from the transmission.
INSTALLATION
(1) Shift transmission into third gear.
(2) Clean the mating surfaces of shift tower, isola-
tor plate and transmission gear case with suitable
wax and grease remover.(3) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission. Do not over
apply sealant.
(4) Install isolator plate onto the transmission,
metal side down.
(5) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and iso-
lator plate.
(6) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(7) Install shift tower bolts and tighten the shift
tower bolts to 8-10 N´m (7-9 ft. lbs.).
(8) Install shift lever extension, shift boot and
bezel.
Fig. 100 SHIFT TOWER
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 101 SHIFT TOWER ISOLATOR PLATE
1 - ISOLATOR PLATE
2 - TRANSMISSION
DRMANUAL TRANSMISSION - NV5600 21 - 129

AUTOMATIC TRANSMISSION - 48RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 48RE
DESCRIPTION........................132
OPERATION..........................134
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................140
DIAGNOSIS AND TESTING - PRELIMINARY . 140
DIAGNOSIS AND TESTING - ROAD
TESTING...........................140
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................141
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION........................144
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................144
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS...........................145
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................158
REMOVAL............................158
DISASSEMBLY........................160
CLEANING...........................166
INSPECTION.........................166
ASSEMBLY...........................166
INSTALLATION........................174
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............176
SPECIFICATIONS
TRANSMISSION.....................189
SPECIAL TOOLS
RE TRANSMISSION..................191
ACCUMULATOR
DESCRIPTION........................193
OPERATION..........................193
INSPECTION.........................194
BANDS
DESCRIPTION........................194
OPERATION..........................194
ADJUSTMENTS
ADJUSTMENT - BANDS...............195
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION........................196
OPERATION..........................196
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......196
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................196ELECTRONIC GOVERNOR
DESCRIPTION........................197
OPERATION..........................198
REMOVAL............................199
INSTALLATION........................200
EXTENSION HOUSING SEAL
REMOVAL............................201
INSTALLATION........................201
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............201
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................201
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................202
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................202
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............203
STANDARD PROCEDURE - TRANSMISSION
FILL...............................204
FRONT CLUTCH
DESCRIPTION........................205
OPERATION..........................205
DISASSEMBLY........................205
INSPECTION.........................206
ASSEMBLY...........................207
FRONT SERVO
DESCRIPTION........................208
OPERATION..........................208
DISASSEMBLY........................209
CLEANING...........................209
INSPECTION.........................209
ASSEMBLY...........................209
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................210
REMOVAL............................210
INSTALLATION........................211
ADJUSTMENTS
GEARSHIFT CABLE..................212
OIL PUMP
DESCRIPTION........................213
OPERATION..........................213
DISASSEMBLY........................214
CLEANING...........................214
INSPECTION.........................214
ASSEMBLY...........................214
21 - 130 AUTOMATIC TRANSMISSION - 48REDR

OUTPUT SHAFT FRONT BEARING
REMOVAL............................216
INSTALLATION........................216
OUTPUT SHAFT REAR BEARING
REMOVAL............................216
INSTALLATION........................217
OVERDRIVE CLUTCH
DESCRIPTION........................217
OPERATION..........................217
OVERDRIVE UNIT
REMOVAL............................218
DISASSEMBLY........................218
CLEANING...........................225
INSPECTION.........................225
ASSEMBLY...........................226
INSTALLATION........................235
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION........................236
OPERATION..........................236
DISASSEMBLY........................236
CLEANING...........................236
INSPECTION.........................237
ASSEMBLY...........................237
PISTONS
DESCRIPTION........................239
OPERATION..........................239
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION........................241
OPERATION..........................241
DISASSEMBLY........................242
INSPECTION.........................243
ASSEMBLY...........................244
REAR CLUTCH
DESCRIPTION........................247
OPERATION..........................248
DISASSEMBLY........................248
CLEANING...........................248
INSPECTION.........................248
ASSEMBLY...........................249
REAR SERVO
DESCRIPTION........................251
OPERATION..........................251
DISASSEMBLY........................251
CLEANING...........................251
ASSEMBLY...........................251
SHIFT MECHANISM
DESCRIPTION........................252OPERATION..........................252
SOLENOID
DESCRIPTION........................252
OPERATION..........................252
SPEED SENSOR
DESCRIPTION........................253
OPERATION..........................253
THROTTLE VALVE CABLE
DESCRIPTION........................253
ADJUSTMENTS - THROTTLE VALVE CABLE . 254
TORQUE CONVERTER
DESCRIPTION........................255
OPERATION..........................259
REMOVAL............................260
INSTALLATION........................260
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION........................261
OPERATION..........................261
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE........261
TOW/HAUL OVERDRIVE SWITCH
DESCRIPTION........................261
OPERATION..........................262
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS..............262
REMOVAL............................262
INSTALLATION........................262
TRANSMISSION RANGE SENSOR
DESCRIPTION........................263
OPERATION..........................263
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)................264
REMOVAL............................265
INSTALLATION........................266
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION........................267
OPERATION..........................267
VALVE BODY
DESCRIPTION........................267
OPERATION..........................272
REMOVAL............................286
DISASSEMBLY........................287
CLEANING...........................298
INSPECTION.........................298
ASSEMBLY...........................299
INSTALLATION........................309
ADJUSTMENTS - VALVE BODY...........310
DRAUTOMATIC TRANSMISSION - 48RE 21 - 131