1998 DODGE RAM 1500 Workshop Manual

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Page 1705 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual Fig. 1 NV3500 TRANSMISSION
21 - 2 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

Page 1706 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual 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. Leaks can occur at th

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. Leaks can occur at the
mating surfaces of the gear case, adaptor or exten-
sion housing, or from the front/rear seals. A sus-
pected leak could also be the result of an overfill
condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent 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 dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations 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.
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.
Shift component damage or damaged clutch pres-
sure plate or disc are additional probable causes of
increased shift effort. 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 gener-
ally 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 and bearing
damage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Raise vehicle on hoist.
(6) Remove skid plate, if equipped.
(7) Drain lubricant if transmission will be disas-
sembled for service.
(8) Mark propeller shaft/shafts and companion
flange yoke/yokes for installation reference and
remove propeller shaft/shafts.
(9) Disconnect harness from clips on transmission
housing.
(10) Remove transfer case linkage if equipped.
(11) Remove transfer case mounting nuts and
remove transfer case if equipped.
(12) Remove slave cylinder mounting nut and
remove cylinder (Fig. 2).
Fig. 2 SLAVE CYLINDER
1 - MOUNTING NUTS
2 - SLAVE CYLINDER
DRMANUAL TRANSMISSION - NV3500 21 - 3
MANUAL TRANSMISSION - NV3500 (Continued)

Page 1707 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (13) Remove starter motor, structural dust cover
bolts to clutch housing, dust shield bolt and suspen-
sion crossmember (Fig. 3).
CAUTION: Do not remove structural dust cover
from enigne block. If cov

Page 1708 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (6) Remove shift shaft lock bolt (Fig. 7) from the
top of front housing. The bolt secures the shift shaft
bushing and lever.
NOTE: This is a special bolt and can not be substi-
tuted with any other bo

Page 1709 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (12) Remove bolts that attach front housing to the
rear housing (Fig. 11). Three bolts at extreme rear of
housing are for the output shaft bearing retainer.
Leave one bolt in place until geartrain is

Page 1710 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (15) Note position of input shaft, shift shaft, forks
and geartrain components in housing (Fig. 14).
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Place a shop towel over the shaft lever to con-
tai

Page 1711 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (6) Drive out shift bushing and lever roll pin with
a hammer and punch (Fig. 17).
NOTE: Use proper size punch to avoid bending the
shift shaft.
(7) Pull shift shaft straight out of rear housing,
shift

Page 1712 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (11) Remove reverse idler shaft support bolt and
loosen rear reverse idler shaft bolt (Fig. 22).
(12) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(13) Support gea

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