1998 DODGE RAM 1500 transmission

(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)

(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