1998 DODGE RAM 1500 Head bolt

(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.
(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.).
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 115 SEAL HOUSINGS
1 - HOUSING FLANGE SURFACE
2 -GASKET MAKER
Fig. 116 HOUSING BOLTS
1 - HOUSING BOLTS
21 - 36 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(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.
(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).
Fig. 117 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
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
DRMANUAL TRANSMISSION - NV3500 21 - 37
MANUAL TRANSMISSION - NV3500 (Continued)

DISASSEMBLY
(1) Clean exterior of transmission with suitable
solvent or pressure washer.
(2) Place transmission in vertical position.
(3) Measure the input shaft end play as follows
(Fig. 17).
(a) Attach Adapter 8266-5 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-5 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. Record the maximum travel for assembly ref-
erence
(4) Remove the overdrive unit from the main
transmission case. If overdrive unit is not to be ser-
viced, install Alignment Shaft 6227-2 into the over-
drive unit to prevent misalignment of the overdrive
clutches during service of main transmission compo-
nents.
(5) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft.
(6) Remove transmission oil pan and gasket.(7) Remove filter from valve body (Fig. 18). Keep
filter screws separate from other valve body screws.
Filter screws are longer and should be kept with fil-
ter.
(8) Remove the transmission range sensor.
(9) Remove hex head bolts attaching valve body to
transmission case (Fig. 19). A total of 10 bolts are
used. Note different bolt lengths for assembly refer-
ence.
Fig. 19 Valve Body Bolt Locations
1 - VALVE BODY BOLTS
2 - VALVE BODY BOLTS
Fig. 17 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
Fig. 18 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
21 - 160 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

ADJUSTMENTS - THROTTLE VALVE CABLE
A correctly adjusted throttle valve cable will cause
the throttle lever on the transmission to move simul-
taneously with the throttle body lever from the idle
position. Proper adjustment will allow simultaneous
movement without causing the transmission throttle
lever to either move ahead of, or lag behind the lever
on the throttle body.
ADJUSTMENT VERIFICATION
(1) Turn ignition key to OFF position.
(2) Remove air cleaner.
(3) Verify that lever on throttle body is at curb idle
position (Fig. 224). Then verify that the transmission
throttle lever (Fig. 225) is also at idle (fully forward)
position.
(4) Slide cable off attachment stud on throttle body
lever.
(5) Compare position of cable end to attachment
stud on throttle body lever:
²Cable end and attachment stud should be
aligned (or centered on one another) to within 1 mm
(0.039 in.) in either direction (Fig. 226).
²If cable end and attachment stud are misaligned
(off center), cable will have to be adjusted as
described in Throttle Valve Cable Adjustment proce-
dure.
Fig. 225 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
2 - THROTTLE VALVE CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(1OR2)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
Fig. 226 Throttle Valve Cable at Throttle Linkage
1 - THROTTLE LINKAGE
2 - THROTTLE VALVE CABLE LOCKING CLIP
3 - THROTTLE VALVE CABLE
Fig. 224 Throttle Valve Cable Attachment - At
Engine
1 - THROTTLE VALVE CABLE
2 - CABLE BRACKET
3 - THROTTLE BODY LEVER
4 - ACCELERATOR CABLE
5 - SPEED CONTROL CABLE
21 - 254 AUTOMATIC TRANSMISSION - 48REDR
THROTTLE VALVE CABLE (Continued)

(20) Reaching through a case opening in the valve
body area with a long blunted tool, remove the trans-
mission front cover from the transmission case.
(21) Remove the bolts holding the oil pump into
the transmission case (Fig. 22).
(22) Remove the oil pump. Hold inward on the
input shaft to prevent pulling the input clutch
assembly with the oil pump (Fig. 22).
NOTE: If the input shaft is not held during oil pump
removal, the input clutch assembly will attempt to
move forward with the oil pump and the numbers 2,
3, or 4 bearings inside the input clutch assembly
may become dislodged.
(23) Remove the number 1 bearing from the input
clutch assembly (Fig. 23).
(24) Remove the input clutch assembly from the
transmission case (Fig. 23).
(25) Remove the number 5 bearing and selective
thrust plate from the input clutch assembly (Fig. 23),
or the 4C clutch retainer/bulkhead.
(26) Remove the 4C clutch retainer/bulkhead
tapered snap-ring from the transmission case (Fig.
24).
(27) Remove the 4C clutch retainer/bulkhead from
the transmission case (Fig. 24).
Fig. 22 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 23 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 24 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 323
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(31) Install the output shaft selective thrust plate
onto the reaction annulus with the oil grooves facing
the annulus gear and the tabs and notches aligned as
shown in (Fig. 42).
(32) Install the number 6 bearing against the out-
put shaft selective thrust plate with the flat side
against the thrust plate (Fig. 41) and the raised tabs
on the inner race facing the front of the transmis-
sion.
(33) Install the reaction annulus into the reaction
planetary gear set (Fig. 41).
(34) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the
reaction annulus during the installation of the 4C
retainer/bulkhead to ease installation.
(35) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case (Fig. 43) with
the taper toward the front of the case. Make sure
that the open ends of the snap-ring are located in the
case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
(37) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 44). The correct output shaft end-play is
0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary.
Install the chosen output shaft selective thrust plate
and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the
extension/adapter housing onto the transmission
case.(39) Install and torque the bolts to hold the exten-
sion/adapter housing onto the transmission case. The
correct torque is 54 N´m (40 ft.lbs.).
(40) Install the number 5 bearing and selective
thrust plate onto the 4C retainer/bulkhead (Fig. 45).
Be sure that the outer race of the bearing is against
the thrust plate.
(41) Install the input clutch assembly into the
transmission case (Fig. 45). Make sure that the input
clutch assembly is fully installed by performing a
Fig. 42 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 43 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 44 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 331
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

Description N´m Ft. Lbs. In. Lbs.
Instrument panel top bolts 12 9 Ð
Load floor nuts 25 18 Ð
Load floor/rear seat bolts 40 30 Ð
Lower seat belt anchor bolt - quad cab 40 30 Ð
Overhead/b-pillar grab handle bolts 6 Ð 55
Radiator and condenser to radiator crossmember bolts 8 Ð 75
Radiator upper crossmember bolts 28 21 Ð
Rear door glass lift plate nuts 10 Ð 89
Rear door glass run channels 10 Ð 89
Rear door hinge to b-pillar bolts 28 21 Ð
Rear door hinge to door bolts/nuts 28 21 Ð
Rear door inside handle bolt 9 Ð 80
Rear door latch adjustment screw 3 Ð 30
Rear door latch bolts 10 Ð 89
Rear door latch striker bolts 28 21 Ð
Rear door regulator bolts 10 Ð 89
Rear door regulator stabilizer nuts 10 Ð 89
Rear door remote handle actuator nuts 10 Ð 89
Rear fender bottom screws 7 Ð 60
Rear fender nuts 7 Ð 60
Rear fender support bracket bolts 11 8 Ð
Rear seat assembly bolts*40 30 Ð
Rear seat back hinge bolts*25 18 Ð
Rear seat cushion hinge bolts*32 24 Ð
Rear shoulder belt anchor bolts 40 30 Ð
Rear view mirror set screw 1 Ð 15
Shifter knob nut 27 20 Ð
Side view mirror nuts 7 Ð 60
Tailgate check cable bolt 23 17 Ð
Tailgate hinge/pivot screws 34 25 Ð
Tailgate latch bolts 23 17 Ð
Tailgate latch striker 34 25 Ð
Tailgate release handle nuts 7 Ð 60
NOTE: *Seat fasteners should be discarded and
replaced with new fasteners during assembly.
DRBODY 23 - 13
BODY (Continued)

TAILGATE
TABLE OF CONTENTS
page page
CHECK CABLE
REMOVAL.............................15
INSTALLATION.........................15
COVER
REMOVAL.............................16
INSTALLATION.........................16
HINGE
REMOVAL.............................16
INSTALLATION.........................16
LATCH
REMOVAL.............................16INSTALLATION.........................16
LATCH STRIKER
REMOVAL.............................16
INSTALLATION.........................17
RELEASE HANDLE/LATCH REMOTE
REMOVAL.............................17
INSTALLATION.........................17
TAILGATE
REMOVAL.............................17
INSTALLATION.........................17
CHECK CABLE
REMOVAL
(1) Open tailgate.
(2) Pry lock tab outward to clear stud head on
cargo box (Fig. 1).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end.
(4) Separate cable end from stud.
(5) Remove screw attaching cable to tailgate. (Fig.
2)
(6) Separate check cable from tailgate.
INSTALLATION
(1) Position check cable on tailgate.
(2) Install bolt attaching small end of cable to tail-
gate.
(3) Tighten tailgate check cable bolt to 23 N´m (17
ft. lbs.).
(4) Position large end of cable onto stud head and
slide downward to secure lock tab.
Fig. 1 Tailgate Check
1 - TAILGATE STRIKER
2 - SCREW DRIVER
3 - TAILGATE CHECK CABLE
4 - LOCK TAB
Fig. 2 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
2 - CONTROL ASSEMBLY
3 - NUTS (2)
4 - TAILGATE
5-LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
DRTAILGATE 23 - 15