1998 DODGE RAM 1500 Reverse

(39) Roll gear case onto its left side.
(40) Grip mainshaft at pilot bearing hub and just
behind reverse gear. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
(41) Continue holding front of shaft but switch
grip at rear to shaft output splines. Lift mainshaft
assembly slightly, align gears and seat assembly in
case.
(42) Set transmission case upright (Fig. 108).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 109). Use plenty of petroleum jelly to hold bear-
ing in place.
(44) Check alignment and mesh of mainshaft
gears. If gears are not aligned, roll case on side and
realign shaft and gears in case.DRIVE GEAR AND RETAINER
(1) Install bearing on drive gear with Installer
6448 (Fig. 110).
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear
rearward until mainshaft hub is seated in pilot bear-
ing.
(4) Install bearing cup in front retainer with Han-
dle C-4171 and Installer C-4308 (Fig. 111).
Fig. 108 MAINSHAFT AND GEARTRAIN IN CASE
1 - MAINSHAFT AND GEARTRAIN
2 - FOURTH SPEED CLUTCH GEAR
Fig. 109 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 110 FRONT BEARING ON DRIVE GEAR
1 - INSTALLER
2 - BEARING
3 - DRIVE GEAR
Fig. 111 FRONT BEARING CUP IN RETAINER
1 - INSTALLER
2 - HANDLE
3 - WOOD BLOCKS
4 - RETAINER
21 - 74 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(10) Tighten fifth gear nut with Nut Wrench 6743
and high capacity torque wrench. Tighten nut to 366-
380 N´m (270-280 ft. lbs.). Have helper hold trans-
mission steady if necessary.
(11) Torque the fifth gear clamp nut clamping bolt
to 13.5 N´m (10 ft. lbs.).
(12) Unlock the mainshaft gears by shifting all
synchro sleeves out of the engaged position.
EXTENSION/ADAPTER HOUSING
(1) Clean mating surfaces of extension/adapter
housing and gear case with a wax and grease
remover.
(2) Check alignment dowels in gear case and hous-
ing or adapter. Be sure dowels are in position and
seated.
(3) Apply Mopar Silicone Sealer or equivalent to
gear case and housing mating surfaces.
(4) Align and install extension/adapter housing on
gear case (Fig. 128).
(5) Apply Mopar Lock N' Seal or equivalent to
threads of extension/adapter housing bolts.
(6) Install and tighten housing bolts to 54 N´m (40
ft. lbs.).SHIFT MECHANISM
(1) Clean mating surfaces of shift cover and gear
case with wax and grease remover.
(2) Apply a small amount of Mopar silicone sealer
or equivalent to sealing surface of shift cover.
CAUTION: Do not over-apply an excesive amount
sealer. Excess can squeezed into gear case and
could block lubricant feed holes in time.
(3) Lubricate synchro sleeves with CastroltSyn-
torq gear lubricant or equivalent. Then apply light
coat of petroleum jelly to shift fork contact surfaces.
(4) Verify shift fork pads (Fig. 129) are secure.
(5) Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
(6) Align and seat shift cover on transmission.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
(7) Apply Mopar Lock N' Seal or equivalent to
threads of shift cover bolts.
(8) Install shift cover bolts and tighten to 27-31
N´m (216-276 in. lbs.).
(9) Apply sealer to backup lamp switch. Install
switch into cover and tighten to 22-34 N´m (193-265
in. lbs.).
(10) Install vent assembly if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
Fig. 128 INSTALLING EXTENSION/ADAPTER
HOUSING
1 - GEAR CASE
2 - EXTENSION HOUSING
Fig. 129 SHIFT FORK PAD
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
DRMANUAL TRANSMISSION - NV4500 21 - 79
MANUAL TRANSMISSION - NV4500 (Continued)

(2) Install housing seal with Handle C-4171 (Fig.
133) and Installer.
²Light Duty - Installer C-3972-A
²Heavy Duty - Installer 8154
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
SHIFT MECHANISM
REMOVAL
(1) Remove transmission from vehicle.
(2) Remove shift mechanism cover bolts.
(3) Pry up shift mechanism cover at slots provided
in cover (Fig. 134).
(4) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 135).
(5) Raise front of shift mechanism cover and lift
cover up and off gear case (Fig. 135).
FIFTH-REVERSE SHIFT FORK PADS
Three shift pads on the forks are held in place by
tension and a small locating tang (Fig. 136).
To remove the pads, grasp a pad with hand and tilt
it out and off the fork. If pad is difficult to remove by
hand, insert a screwdriver blade between the pad
and fork and pry the pad off.
EXPANSION PLUG
The expansion plugs at the rear of the shift rail
bores (Fig. 137) can be replaced if loose/leaking.
(1) Drill 6 mm (1/4 in.) diameter hole in center of
the plug to be removed.
(2) Pry plug out of cover with tapered punch.
Fig. 133 Pinion Seal
1 - HANDLE
2 - INSTALLER
Fig. 134 LOOSEN SHIFT MECHANISM
1 - SHIFT MECHANISM COVER SLOT
2-PRYTOOL
Fig. 135 SHIFT MECHANISM COVER
1 - SHIFT MECHANISM COVER
2 - ALIGNMENT DOWELS
Fig. 136 SHIFT FORK PAD LOCATIONS
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
21 - 86 MANUAL TRANSMISSION - NV4500DR
EXTENSION HOUSING SEAL (Continued)

(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of Mopar silicone sealer or
equivalent to outer edge of each new plug.
(2) Position each plug in bore and tap into place
with hammer and punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab.
(2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift mechanism
cover and gear case with wax and grease remover.
(2)
Apply a small amount of Mopar silicone sealer or
equivalent to sealing surface of shift mechanism cover.
CAUTION: Do not use an excessive amount sealer.
Excess can squeezed into gear case and could
block lubricant feed holes in time.
(3) Lubricate synchro sleeves with CastroltSyn-
torq gear lubricant or equivalent. Then apply light
coat of petroleum jelly to shift fork contact surfaces.
(4) Verify shift fork pads (Fig. 138) are secure.
(5) Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
(6) Align and seat shift mechanism cover on trans-
mission.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
(7) Apply Mopar Lock N' Seal or equivalent to
threads of shift cover bolts.
(8) Install shift cover mechanism bolts and tighten
to 27-31 N´m (216-276 in. lbs.).(9)
Apply sealer to backup lamp switch. Install switch
into cover and tighten to 22-34 N´m (193-265 in. lbs.).
(10) Install vent assembly if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
(11) Install transmission.
SHIFT COVER
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission shift cover.
(5) Remove the shift tower and isolator plate from
the transmission shift cover.
INSTALLATION
(1) Clean the mating surfaces of shift tower, isola-
tor plate and shift cover with suitable wax and
grease remover.
(2) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(3) Install the isolator plate onto the shift cover,
metal side down.
(4) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(5) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(6) Install bolts to hold the shift tower to the iso-
lator plate and the shift cover. Tighten the shift
tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(7) I
nstall shift lever extension, shift boot and bezel.
Fig. 137 EXPANSION PLUG LOCATION
1 - EXPANSION PLUGS
Fig. 138 SHIFT FORK PAD
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
DRMANUAL TRANSMISSION - NV4500 21 - 87
SHIFT MECHANISM (Continued)

MANUAL TRANSMISSION - NV5600
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV5600
DESCRIPTION.........................88
OPERATION...........................90
DIAGNOSIS AND TESTING................90
REMOVAL.............................90
DISASSEMBLY.........................91
CLEANING - TRANSMISSION.............106
INSPECTION.........................106
ASSEMBLY...........................106
INSTALLATION........................121
SPECIFICATIONS - NV5600..............123SPECIAL TOOLS.......................123
ADAPTER HOUSING SEAL
REMOVAL............................128
INSTALLATION........................128
EXTENSION HOUSING SEAL
REMOVAL............................128
INSTALLATION........................128
SHIFT COVER
REMOVAL............................129
INSTALLATION........................129
MANUAL TRANSMISSION -
NV5600
DESCRIPTION
The NV5600 is a six speed constant mesh manual
transmission (Fig. 1). All gear ranges including
reverse are synchronized. First and second gears uti-
lize dual cone synchronizers in order to aid shifting.
Sixth gear is an overdrive range. The transmission
uses cast iron for the gear case and extension/
adapter housing and aluminum for the clutch hous-
ing.To drain the trans remove the bottom PTO cover
bolt. Fill the trans through the plug to the rear of the
PTO cover (Fig. 1). Dry fill is approximately 4.5 liters
(9.5 pints) or to the bottom edge of the fill plug hole.
The gear ratios are:GEAR RATIOS
GEAR RATIO
FIRST 5.63:1
SECOND 3.38:1
THIRD 2.04:1
FOURTH 1.39:1
FIFTH 1.00:1
SIXTH 0.73:1
REVERSE 5.63:1
21 - 88 MANUAL TRANSMISSION - NV5600DR

(6) Remove primary shift rail detent plunger (Fig.
9).
(7) Remove clutch housing bolts (10) (Fig. 10) from
inside the housing.(8) Remove shift rail blocker bolt (Fig. 11) from the
side of the transmission gear case.
EXTENSION/ADAPTER HOUSING
(1) Remove bolts holding the extension/adapter
housing onto the transmission gear case.
(2) Remove extension/adapter housing from the
transmission gear case with Puller 8244 (Fig. 12).
NOTE: It may be necessary to straighten the housing
during removal due to the tendency for the reverse
idler shaft to bind into one side of the housing.
Fig. 9 PRIMARY SHIFT RAIL DETENT PLUNGER
1 - DETENT PLUNGER
Fig. 10 CLUTCH HOUSING BOLTS
1 - BOLTS (10)
Fig. 11 SHIFT RAIL BLOCKER BOLT
1 - BLOCKER BOLT
Fig. 12 TRANSMISSION CASE PULLER
1 - PULLER
2 - EXTENSION/ADAPTER HOUSING
DRMANUAL TRANSMISSION - NV5600 21 - 93
MANUAL TRANSMISSION - NV5600 (Continued)

REVERSE GEAR
(1) Remove crossover cam rollers and pin (Fig. 17).
(2) Remove reverse idler thrust washer from the
reverse idler.
(3) Remove reverse idler and reverse countershaft
gears together (Fig. 18).(4) Remove reverse idler gear rear bearing, bear-
ing spacer, front bearing and front thrust washer
from the idler gear shaft.
(5) Remove reverse countershaft rear bearing from
the countershaft reverse gear assembly with Puller
C-293-PA and Adapters C-293-52 (Fig. 19).
(6) Seperate countershaft reverse gear and sleeve.
(7) Remove output shaft nut with Wrench 8226 on
the shaft nut and Socket 6993 or 6984 to hold the
shaft (Fig. 20). Discard output shaft nut from the
output shaft.
NOTE: If necessary strike the flat side area of
Wrench 8226 with a hammer to break the nut loose.
Fig. 17 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 18 REVERSE IDLER AND COUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 19 COUNTERSHAFT REAR BEARING PULLER
1 - PULLER
2 - ADAPTERS
Fig. 20 LOOSEN OUTPUT SHAFT NUT
1 - WRENCH
2 - SOCKET
DRMANUAL TRANSMISSION - NV5600 21 - 95
MANUAL TRANSMISSION - NV5600 (Continued)

(8) Remove output shaft ball bearing assembly and
reverse thrust washer from the output shaft (Fig.
21).
(9) Remove reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring and reverse
gear bearing (Fig. 22).(10) Remove reverse gear bearing sleeve from the
output shaft (Fig. 23).
NOTE: If necessary heat the sleeve slightly with a
heat gun. Do not use a torch to heat the sleeve or
damage to the output shaft may occur.
(11) Remove roll-pin securing the reverse shift fork
to the reverse shift rail witha6mm(7/32 in.) punch
and hammer.
Fig. 21 OUTPUT SHAFT BEARING AND THRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
Fig. 22 REVERSE GEAR COMPONENTS
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
Fig. 23 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
21 - 96 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)