1998 DODGE RAM 1500 one

(9) Invert output shaft and set the shaft in Collar
6310-1 so fifth gear is seated on the tool (Fig. 58).
(10) Install first gear bearing on output shaft (Fig.
58). Verify bearing is seated on shaft shoulder and is
properly joined.
(11) Install first gear on shaft and over bearing
(Fig. 59) with bearing synchro cone facing up.(12) Install first gear synchro ring (Fig. 60).
(13) Start 1-2 synchro assembly on shaft by hand
(Fig. 61).
CAUTION: One side of the synchro sleeve is
marked First Gear Side, this side must face first
gear.
Fig. 58 FIRST GEAR
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - COLLAR
4 - PRESS BLOCKS
Fig. 59 FIRST GEAR
1 - FIRST GEAR
2 - COLLAR
3 - BEARING
Fig. 60 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
2 - COLLAR
3 - FIRST GEAR
Fig. 61 STARTING 1-2 SYNCHRO
1 - 1-2 SYNCHRO ASSEMBLY
2 - COLLAR
3 - FIRST GEAR SIDE
21 - 20 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(14) Press 1-2 synchro onto output shaft using
suitable size pipe and shop press (Fig. 62).
CAUTION: Keep synchro ring and sleeve aligned as
the hub is being pressed onto the shaft. The syn-
chro ring can be cracked if it becomes misaligned.
(15) Install interm ring.
(16) Installnew1-2 synchro hub snap ring (Fig.
63). Verify snap ring is seated in shaft groove.
(17) Install second gear synchro ring in 1-2 syn-
chro hub and sleeve (Fig. 64). Verify synchro ring is
seated in sleeve.
(18) Install synchro friction cone and synchro cone
in synchro ring.
Fig. 62 1-2 SYNCHRO ON OUTPUT SHAFT
1 - PIPE TOOL
2 - SYNCHRO RING
3 - COLLAR
4 - 1-2 SYNCHRO ASSEMBLY
5 - PRESS RAM
Fig. 63 1-2 SYNCHRO HUB SNAP RING
1 - 1-2 SYNCHRO
2 - COLLAR
3 - SYNCHRO SNAP RING
Fig. 64 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - COLLAR
DRMANUAL TRANSMISSION - NV3500 21 - 21
MANUAL TRANSMISSION - NV3500 (Continued)

(19) Install second gear needle bearing on shaft
(Fig. 65).
(20) Install second gear onto shaft and bearing
(Fig. 66). Verify second gear is seated on synchro
components.
(21) Install two-piece thrust washer with halves
seated in the shaft groove and washer lugs seated in
shaft lug bores (Fig. 67). Verify i.d. grooves and
markings noted during removal are facing the correct
direction.
(22) Start retaining ring around two-piece thrust
washer (Fig. 68). Verify locating dimple is between
thrust washer halves.
Fig. 65 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - COLLAR
Fig. 66 SECOND GEAR
1 - COLLAR
2 - 1-2 SYNCHRO ASSEMBLY
3 - BEARING
4 - SECOND GEAR
Fig. 67 TWO-PIECE THRUST WASHER
1 - WASHER GROOVE IN SHAFT
2 - LUG BORE
3 - THRUST WASHER LUGS
4 - LUG BORE
5 - LUG
6 - WASHER HALF
Fig. 68 RETAINING RING
1 - THRUST WASHER RETAINING RING
2 - THRUST WASHER HALVES
3 - SECOND GEAR
4 - LOCATING DIMPLE
21 - 22 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(23) Seat thrust washer retaining ring with plastic
mallet (Fig. 69).
(24) Install third gear needle bearing on shaft (Fig.
70).
(25) Install third gear on shaft and bearing (Fig.
71).
(26) Install third speed synchro ring on third gear
(Fig. 72).
(27) Start 3-4 synchro hub on output shaft splines
by hand (Fig. 73).
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the sleeve has grooves in it, this side must
faces the front of the shaft.
Fig. 69 THRUST RETAINER
1 - PLASTIC MALLET
2 - THRUST WASHER RETAINING RING
Fig. 70 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 71 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 72 THIRD GEAR SYNCHRO RING
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 73 3-4 SYNCHRO HUB ON OUTPUT SHAFT
1 - GROOVED SIDE OF SLEEVE
2 - 3-4 SYNCHRO ASSEMBLY
DRMANUAL TRANSMISSION - NV3500 21 - 23
MANUAL TRANSMISSION - NV3500 (Continued)

(28) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to
output shaft as possible but not contacting the
shaft splines.
(29) Installnew3-4 synchro hub snap ring (Fig.
75). Verify snap ring is seated in groove.(30) Install output shaft bearing.
(31) Install output shaft bearing snap ring with
heavy duty snap ring pliers (Fig. 76). Verify snap
ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
(32) Verify position of synchro sleeves before pro-
ceeding (Fig. 77). Grooved side of 3-4 sleeve must
face forward. First gear side of 1-2 sleeve must face
first gear. Tapered side of fifth-reverse sleeve must
face forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube.
(2) Slide idler gear bearing on shaft (Fig. 78).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 78).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 78). Petroleum jelly can be used to
hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 79).
(6) Install snap ring in groove at rear of shaft (Fig.
79).
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
Fig. 74 3-4 SYNCHRO ON OUTPUT SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 75 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 76 OUTPUT SHAFT BEARING SNAP
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
21 - 24 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

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)