1998 DODGE RAM 1500 manual transmission

(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 geartrain and rear housing on Fix-
ture 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2A on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 23).
(d) Stand geartrain and rear housing upright on
fixture (Fig. 24). Have helper hold fixture tool in
place while housing and geartrain is being rotated
into upright position.(14) Remove rear bolt holding reverse idler shaft
in housing.
Fig. 22 REVERSE IDLER SHAFT & SUPPORT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 23 FIXTURE ASSEMBLY
1 - FIXTURE 6747
2 - ADAPTER 6747-1A
3 - CUP ADAPTER 8115
4 - REVERSE IDLER PEDESTAL
5 - ADAPTER 6747-2A
Fig. 24 GEARTRAIN & HOUSING ON FIXTURE
1 - INPUT SHAFT
2 - COUNTERSHAFT
3 - FIXTURE 6747
DRMANUAL TRANSMISSION - NV3500 21 - 9
MANUAL TRANSMISSION - NV3500 (Continued)

REAR HOUSING - 2WD
(1) On 2-wheel drive transmission, remove three
bolts that attach output shaft bearing retainer to
rear case (Fig. 25). Bolts are rear of shift tower open-
ing.
(2) Tap rear housing upward and off output shaft
bearing with a plastic/rawhide hammer (Fig. 26).
(3) Lift rear housing up and off geartrain (Fig. 27).
Fig. 26 SEPARATE REAR HOUSING & OUTPUT
SHAFT BEARING
1 - REAR HOUSING
2 - MALLET
3 - FIXTURE
Fig. 27 REAR HOUSING - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 25 OUTPUT SHAFT
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
21 - 10 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(4) Remove countershaft rear bearing from coun-
tershaft (Fig. 28).
REAR ADAPTER HOUSING - 4WD
(1) Inserting screw from slide hammer (Fig. 29)
into one of the dimples in face of rear seal (Fig. 30)
and remove seal.
(2) Remove rear bearing snap ring from output
shaft (Fig. 31).
(3) Lift rear adapter housing upward and off
geartrain (Fig. 32).
(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 33). Push or
tap bearing out of housing with a hammer handle if
needed.
Fig. 28 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - OUTPUT SHAFT
3 - COUNTER SHAFT
Fig. 29 REAR SEAL
1 - SLIDE HAMMER
2 - REMOVER TOOL
3 - REAR SEAL
Fig. 30 REAR SEAL FACE
1 - DIMPLES
2 - SEAL FACE
Fig. 31 REAR BEARING SNAP RING
1 - HEAVY DUTY SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 32 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
DRMANUAL TRANSMISSION - NV3500 21 - 11
MANUAL TRANSMISSION - NV3500 (Continued)

NOTE: Housing must be replaced if race, bearing
bore or idler shaft notch are worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove reverse idler gear assembly from
assembly fixture cup.
(2) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(3) Slide countershaft out of fixture tool.
(4) Remove output shaft bearing retainer from
rear surface of fifth gear (retainer will drop onto gear
after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from the fixture.
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different
and must not be mixed. Remove each synchronizer
unit as an assembly to avoid mixing parts. Mark
each synchro hub and sleeve with a scriber or paint
for correct assembly reference.(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Position Bearing Splitter 1130 between second
and third gears and press off 3-4 synchro assembly,
third gear synchro ring and third gear with a shop
press.
(3) Remove third gear needle bearing (Fig. 34).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft with a small pry tool (Fig.
35).
Fig. 33 REAR ADAPTER HOUSING COMPONENTS
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 34 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 35 THRUST WASHER
1-PRYTOOL
2 - THRUST WASHER RETAINING RING
21 - 12 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(5) Remove two-piece thrust washer (Fig. 36) and
note position of washer locating lugs in shaft notches
for installation reference.
(6) Remove second gear and needle bearing (Fig.
37).
(7) Remove second gear synchro ring, synchro fric-
tion cone, synchro cone and interm ring (Fig. 38).
(8) Remove 1-2 synchro hub snap ring.
(9) Position Bearing Splitter 1130 between first
and reverse gear. Press off 1-2 synchro hub, sleeve
and first gear from output shaft with shop press (Fig.
39).
(10) Remove first gear needle bearing (Fig. 40).
Fig. 36 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2-PIECE)
3 - WASHER LOCATING LUG
Fig. 37 SECOND GEAR
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 38 SECOND GEAR SYNCHRO RING & CONES
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
Fig. 39 HUB SLEEVE & 1-2 SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - BEARING SPLITTER 1130
Fig. 40 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 13
MANUAL TRANSMISSION - NV3500 (Continued)

(11) Remove output shaft bearing snap ring (Fig.
41).
(12) On 2-wheel drive models, remove output shaft
bearing.
(13) Remove fifth gear (Fig. 42).(14) Remove fifth gear needle bearing. Spread
bearing just enough to clear shoulder on output shaft
(Fig. 43).
(15) Remove fifth-reverse synchro hub snap ring
(Fig. 44).
Fig. 41 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 42 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 43 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig. 44 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
21 - 14 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(16) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 45).
(17) Remove reverse gear and needle bearing (Fig.
46).
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
Fig. 45 FIFTH-REVERSE SYNCHRO
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 46 REVERSE GEAR & NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
Fig. 47 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
DRMANUAL TRANSMISSION - NV3500 21 - 15
MANUAL TRANSMISSION - NV3500 (Continued)

INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball or internal components are worn or
damaged.
SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 48). Replace any fork
exhibiting wear or damage in these areas. Do not
attempt to salvage shift forks.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks or scores. The plunger spring should be
straight and not collapsed, or distorted. Minor
scratches or nicks on the plunger can be smoothed
with 320/400 grit emery soaked in oil. Replace the
plunger and spring if in doubt about condition. Check
condition of detent plunger bushings. Replace if dam-
aged.
Inspect shift shaft, shift shaft bushing, bearing,
shaft lever and lever bushing that fits over the lever.
Replace shaft if bent, cracked or severely scored.
Minor burrs, nicks or scratches can be smoothed off
with 320/400 grit emery cloth followed by polishing
with crocus cloth. Replace the shift shaft bushing or
bearing if damaged.Replace the shaft lever and bushing if either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the roll
pin that secures the lever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. These components
are NOT serviceable items. The front housing will
have to be replaced if the countershaft bearing race
is loose, worn or damaged. The rear housing will
have to be replaced if the countershaft rear bearing
race is loose, worn or damaged.
Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth and final
polished with oil coated crocus cloth. Replace the
retainer seal if necessary.
Fig. 48 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
21 - 16 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)