1998 DODGE RAM 1500 Transmission install

(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.
(21) Install and tighten bearing retainer bolts to
7-10 N´m (5-7 ft. lbs.) (Fig. 123).SHIFT TOWER AND LEVER
(1) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(2) Shift the transmission into third gear.
(3) Align and install shift tower and lever assem-
bly (Fig. 124). Be sure shift ball is seated in socket
and the offset in the tower is toward the passenger
side of the vehicle before installing tower bolts.
(4) Install shift tower bolts (Fig. 125) and tighten
bolts to 8.5 N´m (75.2 in. lbs.).
(5) Fill transmission to bottom edge of fill plug
hole with lubricant.
(6) Install and tighten fill plug to 34 N´m (25 ft.
lbs.).
(7) Check transmission vent. Be sure vent is open
and not restricted.
Fig. 122 INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
3 - BEARING RETAINER
Fig. 123 BEARING RETAINER BOLTS - TYPICAL
1 - RETAINER BOLTS
2 - RETAINER
Fig. 124 SHIFT TOWER
1 - SHIFT TOWER
2 - SHAFT SOCKET
3 - SHIFT BALL
Fig. 125 SHIFT TOWER BOLTS
1 - SHIFT TOWER AND LEVER ASSEMBLY
21 - 38 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

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, do not
re-use the original shift tower.
(1) Clean transmission front housing mounting
surface.
(2) Apply light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces (Fig.
126) of following components:
²release fork ball stud.
²release bearing slide surface.
²input shaft splines.
²release bearing bore.
²propeller shaft slip yoke.
(3) Support and secure transmission to jack.
(4) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(5) Verify front housing is fully seated. Install
transmission bolts without washers and tighten bolts
into the engine to 41 N´m (30 ft. lbs.). Tighten the
bolts with washers into the transmission to 68 N´m
(50 ft. lbs.) (Fig. 127).(6) Install rear crossmember and tighten nuts to
102 N´m (75 ft. lbs.).
(7) Install transmission rear mounting bolts and
tighten to 68 N´m (50 ft. lbs.).
(8) Install front dust shield tighten bolt to 4.5 N´m
(40 in. lbs.). If cover was removed, install onto the
transmission and engine(Refer to 9 - ENGINE/EN-
GINE BLOCK/STRUCTURAL COVER - INSTALLA-
TION).
(9) Install structural dust cover and tighten the
bolts to 54 N´m (40 ft. lbs.).
(10) Install starter motor.
(11) Install suspension crossmember and tighten
nuts to 102 N´m (75 ft. lbs.).
(12) Connect transmission harnesses to clips on
case and connect switches.
(13) Install slave cylinder and tighten cylinder
nuts to 23 N´m (200 in. lbs.).
(14) Install transfer case and transfer case linkage
if equipped.
(15) Remove transmission jack.
(16) Install propeller shaft/shafts with reference
marks aligned.
(17) Install exhaust on the exhaust manifolds.
(18) Fill transmission with lubricant. Correct fill
level is to bottom edge of fill plug hole.
Fig. 126 LUBRICATION POINTS
1 - RELEASE FORK
2 - FORK BALL STUD
3 - BEARING SLIDE SURFACE
4 - SPLINE
5 - RELEASE BEAING
Fig. 127 TRANSMISSION
1 - BOLT WITHOUT WASHER
2 - BOLT WITH WASHER
DRMANUAL TRANSMISSION - NV3500 21 - 39
MANUAL TRANSMISSION - NV3500 (Continued)

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crossmember Nuts 102 75 -
Transmission Mount Bolts 4WD 68 50 -
Transmission Mount Bolts 2WD 68 50 -
Structural Dust Cover Bolts 54 40 -
Drain/Fill Plug 9-27 14-20 -
Front To Rear Housing Bolts 30-35 22-26 -
Front Bearing Retainer Bolts 7-10 5-7 62-88
Idler Shaft Bolts 19-25 14-18 -
Rear Bearing Retainer Bolts 30-35 22-26 -
Shift Tower Bolts 7-10 5-7 62-88
Slave Cylinder Nuts 23 17 -
Transfer Case Nuts 47 35 -
SPECIAL TOOLS
REMOVER C-3985-B
INSTALLER C-3972-A
REMOVER 6957
INSTALLER 6951
HANDLE C-4171
21 - 40 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

REMOVER/INSTALLER 6858
FIXTURE 6747
ADAPTER 6747-1A
ADAPTER 6747-2A
CUP 8115
BEARING SPLITTER 1130
TUBE 6310-1
INSTALLER 8118
REMOVER/INSTALLER 8119
ALIGNMENT STUD 8120
DRMANUAL TRANSMISSION - NV3500 21 - 41
MANUAL TRANSMISSION - NV3500 (Continued)

INSTALLER C-3860-A
INSTALLER 8123
INSTALLER 6448
REMOVER 8117A
21 - 42 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

MANUAL TRANSMISSION - NV4500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV4500
DESCRIPTION.........................43
OPERATION...........................43
DIAGNOSIS AND TESTING................44
REMOVAL.............................44
DISASSEMBLY.........................46
CLEANING............................62
INSPECTION..........................62
ASSEMBLY............................63
INSTALLATION.........................80
SPECIFICATIONS.......................81
SPECIAL TOOLS.......................81ADAPTER HOUSING SEAL
REMOVAL.............................85
INSTALLATION.........................85
EXTENSION HOUSING SEAL
REMOVAL.............................85
INSTALLATION.........................85
SHIFT MECHANISM
REMOVAL.............................86
INSTALLATION.........................87
SHIFT COVER
REMOVAL.............................87
INSTALLATION.........................87
MANUAL TRANSMISSION -
NV4500
DESCRIPTION
The NV4500 is a five speed constant mesh manual
transmission. All gear ranges including reverse are
synchronized. Fifth gear is an overdrive range. The
transmission has a cast iron gear case and aluminum
shift cover.
Two versions are used, a standard duty for 5.7L
applications and a heavy duty for V10 and Cummins
diesel applications. Main difference is a larger diam-
eter input shaft, for the heavy duty model.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Roller
bearings in the drive gear support the forward end of
the mainshaft. The mainshaft gears are all supported
on caged type roller bearings. Drive gear thrust reac-
tion is controlled by a needle type thrust bearing.
The bearing is located at the forward end of the
mainshaft.
The transmission is a top loader style. The shift
lever is located in a shifter tower which is bolted to
the shift cover and operates the shift forks and rails
directly. The shift forks and rails are all located
within the aluminum cover which is bolted to the top
of the gear case.
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 1).
The tag provides the transmission model number,
build date and part number. Be sure to reinstall the
I.D. tag if removed during service. The information
on the tag is essential to correct parts ordering.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point all the transmission gears
are spinning.
Fig. 1 IDENTIFICATION TAG LOCATION
1 - PTO COVER
2 - I.D. TAG
DRMANUAL TRANSMISSION - NV4500 21 - 43

(3) Remove rubber spline seal from end of main-
shaft (Fig. 9). The seal is used to prevent lubricant
loss during shipping and does not have to be replaced
if damaged.
FIFTH GEAR NUT
(1) Remove extension/adapter housing.
(2) Loosen fifth gear clamp nut clamping screw
approximately 1 1/2 turns.
(3) Install Wrench 6743 on fifth gear nut (Fig. 10).
NOTE: Wrench only fits one way on nut. Make sure
wrench is fully engaged in nut slots and is not cocked.
(4)Install Socket 6993 4X2 or Socket 6984 4X4 with
breaker bar to hold mainshaft and remove fifth gear nut.
NOTE: Wedge breaker bar handle against workbench.
Purpose of socket wrench and breaker bar is to pre-
vent mainshaft from turning while nut is loosened.
(5) Remove fifth gear nut, then remove belleville
washer from mainshaft.
FIFTH GEAR
(1) Remove fifth gear shift fork roll pins (Fig. 11).
Drive roll pins out from the bottom of fork.
(2) Remove fifth gear clutch hub and gear snap
ring from countershaft (Fig. 12).
(3) Remove countershaft fifth gear clutch gear and
stop ring.
(4) Tap off fifth gear shift fork and gear assembly
off rail with plastic mallet.
(5) Remove fifth gear shift fork from sleeve.
(6) Remove sleeve, struts and strut springs from
countershaft fifth gear hub, if necessary.
Fig. 10 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SPLINE SOCKET
Fig. 9 MAINSHAFT SPLINE SEAL
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 11 FIFTH GEAR SHIFT FORK ROLL PINS
1 - ROLL PINS
2 - FIFTH GEAR SHIFT FORK
Fig. 12 FIFTH GEAR CLUTCH GEAR SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 47
MANUAL TRANSMISSION - NV4500 (Continued)

(12) Position second puller jaw on gear and in
notch of puller flange (Fig. 17). Slide Collar 6444-8
over puller jaws to hold them in place.
(13) Install Puller and Bolt 6444 on puller rods
and secure puller to rods with retaining nuts (Fig.
18). Tighten puller bolt to remove gear from shaft
splines.(14) Remove mainshaft rear bearing plate bolts
and remove fifth gear plate end play shims and bear-
ing cup (Fig. 19).
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 20).
CAUTION: Do not reuse retainer bolts.
(2) Lightly tap retainer back and forth with plastic
mallet to work it out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
Fig. 17 PULLER COLLAR
1-JAWS
2 - COLLAR
Fig. 18 PULLER ASSEMBLY
1 - COLLAR
2-JAWS
3 - BOLT
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE
Fig. 19 FIFTH GEAR BEARING PLATE, SHIMS AND
BEARING CUP
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 20 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
DRMANUAL TRANSMISSION - NV4500 21 - 49
MANUAL TRANSMISSION - NV4500 (Continued)