1998 DODGE RAM 1500 Reverse

GEARTRAIN ASSEMBLY
(1) Install Adapter 6747-1A on input shaft hub of
Fixture 6747 (Fig. 81). Then install Adapter 6747-2A
on front bearing hub of countershaft. Be sure the
shoulder is seated against the countershaft.
(2)
Install input shaft in fixture tool with Adapter Tool
6747-1A positioned under the shaft as shown (Fig. 82).
(3) Install pilot bearing in input shaft (Fig. 82).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.(4) Install fourth gear synchro ring on input shaft
(Fig. 83).
(5) Adjust height of idler gear pedestal on fixture
(Fig. 84). Start with a basic height of 18.4 cm (7-1/4
in.). Final adjustment can be made after gear is posi-
tioned on pedestal.
Fig. 81 FIXTURE FOR GEARTRAIN BUILD-UP
1 - ADAPTER 6747-2A
2 - CUP 8115
3 - ADAPTER 6747-1A
4 - FIXTURE 6747
Fig. 82 PILOT BEARING & INPUT SHAFT
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 83 FOURTH GEAR SYNCHRO
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 84 IDLER PEDESTAL BASE HEIGHT
1 - REVERSE IDLER PEDESTAL
DRMANUAL TRANSMISSION - NV3500 21 - 27
MANUAL TRANSMISSION - NV3500 (Continued)

(6) Install assembled output shaft and geartrain in
input shaft (Fig. 85). Carefully rotate output shaft
until the 3-4 synchro ring seats in synchro hub and
sleeve.
(7) Install Adapter 6747-2A on front bearing hub of
countershaft, if not previously done. The shoulder
goes toward the countershaft.
(8) Slide countershaft (and adapter) into fixture
slot. Verify countershaft and output shaft gears are
fully meshed with the mainshaft gears before pro-
ceeding (Fig. 86).
(9) Check alignment of countershaft and output
shaft gear teeth. Gears may not align perfectly a dif-
ference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.)
will probably exist. This will not interfere with
assembly. If difference is greater than this, the coun-
tershaft adapter tool is probably upside down.
(10) Position reverse idler in support cup of fixture
(Fig. 87). Verify idler gear is properly meshed and
aligned with shaft gear teeth and that bolt holes are
facing out from the geartrain. Adjust pedestal up or
down if necessary and verify short end of idler shaft
is facing up as shown.
Fig. 85 OUTPUT SHAFT, GEARTRAIN & INPUT
SHAFT
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE 6747
Fig. 86 COUNTERSHAFT ON FIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig. 87 REVERSE IDLER ASSEMBLY ON FIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - PEDESTAL
21 - 28 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(11) On 2-wheel drive transmission, thread one
Alignment Pin 8120 in center or passenger side hole
of output shaft bearing retainer. Then position
retainer on fifth gear as shown (Fig. 88).
(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
89). Arm of fifth-reverse fork goes through slot in 1-2
fork.
(13) Install assembled shift forks in synchro
sleeves and verify forks are seated in sleeves (Fig.
90).
REAR HOUSING - 2WD
NOTE: Transmission shift components must be in
Neutral position to prevent damaging the synchro
and shift components when installing the housings.(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 91).
Fig. 88 ALIGN OUTPUT SHAFT BEARING RETAINER
1 - ALIGNMENT PIN
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 89 1-2 & FIFTH-REVERSE SHIFT FORKS
1 - 1-2 FORK
2 - 1-2 FORK ARM
3 - FIFTH-REVERSE FORK
Fig. 90 SHIFT FORKS IN SYNCHRO
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
Fig. 91 REAR HOUSING DOWELS
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
DRMANUAL TRANSMISSION - NV3500 21 - 29
MANUAL TRANSMISSION - NV3500 (Continued)

(9) Install rear bearing snap ring on output shaft
(Fig. 98).
(10) Lubricate lip of new rear seal (Fig. 99) with
Mopar Door Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 99).SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify all synchro sleeves are in Neutral posi-
tion (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position to prevent damaging the housings,
shift forks and gears while installing the housings.
(2) Install 3-4 shift fork in synchro sleeve (Fig.
100). Verify groove in fork arm is aligned with
grooves in 1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
101).
Fig. 98 REAR BEARING SNAP RING
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 99 ADAPTER HOUSING REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
Fig. 100 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 101 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
21 - 32 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(4) Assemble shift shaft shift lever and bushing
(Fig. 102). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 103).(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
104).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 105).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-
mission will have to be disassembled again to cor-
rect shaft alignment.
Fig. 102 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 103 SHIFT SHAFT LEVER AND BUSHING
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 104 SHAFT LEVER OPENING
1 - SHIFT SHAFT
Fig. 105 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
DRMANUAL TRANSMISSION - NV3500 21 - 33
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

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 28).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 29).
(4) Roll gear case onto left side.
(5) Remove mainshaft assembly (Fig. 30) by lifting
front end of mainshaft slightly. Then grasp mainshaft
rear splines and turn spline end of mainshaft coun-
terclockwise to rotate shaft and geartrain out of case.
Tilt mainshaft outward and removed from case.
NOTE: Handling mainshaft carefully because gears
are lose on the mainshaft.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
31).
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 32).
Fig. 28 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 29 FOURTH GEAR CLUTCH GEAR STOP RING
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
Fig. 30 MAINSHAFT AND GEARTRAIN
1 - MAINSHAFT AND CASE
Fig. 31 COUNTERSHAFT REAR BEARING PLATE
1 - REAR BEARING PLATE
2 - COUNTERSHAFT
Fig. 32 END PLAY SHIM AND REAR BEARING CUP
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
21 - 52 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(3) Remove reverse idler shaft (Fig. 33).
(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 34).(5) Remove idler gear (Fig. 35).
(6) Keep reverse idler gear bearings and spacer
together (Fig. 36). Insert idler shaft through gear and
bearings to keep them in place.
(7) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them
together for cleaning and inspection.
Fig. 33 REVERSE IDLER SHAFT
1 - REVERSE IDLER SHAFT
Fig. 34 IDLER GEAR AND COUNTERSHAFT
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT
Fig. 35 REVERSE IDLER GEAR
1 - REVERSE IDLER GEAR
2 - DRIVE GEAR BORE
Fig. 36 IDLER GEAR COMPONENTS
1 - BEARINGS
2 - REVERSE IDLER GEAR
DRMANUAL TRANSMISSION - NV4500 21 - 53
MANUAL TRANSMISSION - NV4500 (Continued)