2001 DODGE RAM Service Repair Manual

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Page 1633 of 2889

DODGE RAM 2001 Service Repair Manual LINKAGE - 4WD
TABLE OF CONTENTS
page page
LINKAGE - 4WD
DESCRIPTION...........................40
STANDARD PROCEDURE..................40
LUBRICATION.........................40REMOVAL...................

Page 1634 of 2889

DODGE RAM 2001 Service Repair Manual INSTALLATION
(1) Align reference marks and install pitman arm.
(2) Install the lock washer and retaining nut on
the pitman shaft and tighten nut to 251 N´m (185 ft.
lbs.).
(3) Install drag link to th

Page 1635 of 2889

DODGE RAM 2001 Service Repair Manual SPECIAL TOOLS
STEERING LINKAGE
Remover Ball Stud MB-991113
Puller Tie Rod C-3894-A
Remover Pitman C-4150A
19 - 42 LINKAGE - 4WDBR/BE

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DODGE RAM 2001 Service Repair Manual TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV3500........................1
MANUAL - NV4500.......................44
MANUAL - NV5600.......................91
AUTOMATIC TRANSMIS

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV3500........................1
MANUAL - NV4500.......................44
MANUAL - NV5600.......................91
AUTOMATIC TRANSMISSION - 42RE........134
AUTOMATIC TRANSMISSION - 44RE........305AUTOMATIC TRANSMISSION - 46RE........477
AUTOMATIC TRANSMISSION - 47RE........648
TRANSFER CASE - NV231HD..............820
TRANSFER CASE - NV241LD..............855
TRANSFER CASE - NV241HD..............890
MANUAL - NV3500
TABLE OF CONTENTS
page page
MANUAL - NV3500
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................3
MANUAL TRANSMISSION.................3
REMOVAL...............................3
DISASSEMBLY............................5CLEANING..............................15
INSPECTION............................15
ASSEMBLY.............................17
INSTALLATION...........................40
SPECIFICATIONS........................41
SPECIAL TOOLS.........................41
MANUAL - NV3500
DESCRIPTION
The NV3500 is a medium-duty 5-speed, constant
mesh fully synchronized manual transmission. Fifth
gear is an overdrive range with a ratio of 0.73:1. The
NV3500 is available in two and four-wheel drive con-
figurations.
The transmission gear case consists of two alumi-
num housings (Fig. 1). The clutch housing is not a
removable component. It is an integral part of the
transmission front housing.
A combination of roller and ball bearings are used
to support the transmission shafts in the two hous-
ings. The transmission gears all rotate on caged type
needle bearings. A roller bearing is used between the
input and output shaft.
The transmission has a single shaft shift mecha-
nism with three shift forks all mounted on the shaft.
The shaft is supported in the front and rear housings
by bushings and one linear ball bearing. Internal
shift components consist of the forks, shaft, shift
lever socket, and detent components
GEAR RATIOS
Gear ratios is as follows:
GEAR RATIO
FIRST 4.02:1
SECOND 2.32:1
THIRD 1.40:1
FOURTH 1:1
FIFTH 0.73:1
REVERSE 3.55:1
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.
BR/BETRANSMISSION AND TRANSFER CASE 21 - 1

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DODGE RAM 2001 Service Repair Manual Fig. 1 NV3500 Manual Transmission
21 - 2 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

Page 1638 of 2889

DODGE RAM 2001 Service Repair Manual The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shif

The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shift lever
moves the selected shift rail, the shift fork attached
to that rail begins to move. The fork is positioned in
a groove in the outer circumference of the synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer does
this by having the synchronizer hub splined to the
mainshaft, or the countershaft in some cases, and
moving the blocker ring into contact with the gear's
friction cone. As the blocker ring and friction cone
come together, the gear speed is brought up or down
to the speed of the synchronizer. As the two speeds
match, the splines on the inside of the synchronizer
sleeve become aligned with the teeth on the blocker
ring and the friction cone and eventually will slide
over the teeth, locking the gear to the mainshaft, or
countershaft, through the synchronizer.
DIAGNOSIS AND TESTING - MANUAL
TRANSMISSION
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incor-
rect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, adaptor or extension housing, or from the front/
rear seals. A suspected leak could also be the result
of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab and or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants. The con-sequence of using non-recommended lubricants is
noise, excessive wear, internal bind and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment or
damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect
adjustment or a worn/damaged pressure plate or disc
can cause incorrect release. If clutch problem is
advanced, gear clash during shifts can result. Worn
or damaged synchro rings can cause gear clash when
shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot bezel screws and slide boot
upward on shift lever extension.
(4) Remove shift lever extension from the shift
tower and lever assembly.
(5) Remove bolts attaching shift tower and lever
assembly to rear case. Then remove shift tower and
lever assembly.
(6) Raise vehicle on hoist.
(7) Remove crankshaft position sensor. Retain sen-
sor attaching bolts.
(8) Remove skid plate, if equipped.
(9) Drain transmission lubricant if transmission
will be disassembled for service.
(10) Mark propeller shaft/shafts and yoke/yokes for
installation reference and remove propeller shaft/
shafts.
(11) Disengage harness from clips on transmission
housing.
(12) Support engine with adjustable jack stand
and wood block.
(13) Drain transmission lubricant if transmission
will be disassembled for service.
BR/BEMANUAL - NV3500 21 - 3
MANUAL - NV3500 (Continued)

Page 1639 of 2889

DODGE RAM 2001 Service Repair Manual TWO WHEEL DRIVE
(1) Remove nuts attaching rear mount to cross-
member (Fig. 2). Then remove insulator from exten-
sion housing if necessary.
(2) Remove bolts and nuts attaching crossmember
to frame ra

TWO WHEEL DRIVE
(1) Remove nuts attaching rear mount to cross-
member (Fig. 2). Then remove insulator from exten-
sion housing if necessary.
(2) Remove bolts and nuts attaching crossmember
to frame rails. Rotate crossmember diagonally and
remove crossmember.
(3) Disconnect exhaust as necessary.
(4) Remove slave cylinder attaching nuts and
remove cylinder from clutch housing.
(5) Remove starter motor.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove nuts/bolts attaching transmission front
housing to engine.
(8) Remove transmission dust shield.
(9) Move transmission rearward until input shaft
is clear of clutch disc and cover. Then lower jack and
remove transmission from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever.
(2) Remove bolts attaching shift linkage bracket to
transfer case and move linkage and bracket aside.
(3) Support transfer case with transmission jack.
(4) Remove nuts attaching transfer case to trans-
mission adapter housing.(5) Remove transfer case with aid of helper.
(6) Support engine with a jack stand and a wood
block.
(7) Remove nuts and bolts attaching support
bracket and cushions to fixed crossmember.
(8) Remove nuts and bolts attaching removable
crossmember to frame rails.
(9) Remove crossmember.
(10) Disconnect exhaust as necessary.
(11) Remove slave cylinder attaching nuts and
remove cylinder from clutch housing. Move cylinder
aside for working clearance.
(12) Remove clutch housing dust cover.
(13) On some models, it may be necessary to
remove front axle struts and oil filter for access and
removal clearance. Remove these components if nec-
essary.
(14) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(15) Remove bolts attaching transmission clutch
housing to engine block.
(16) Move transmission rearward until transmis-
sion input shaft is clear of clutch disc and cover.
Then lower jack and remove transmission from under
vehicle.
Fig. 2 Transmission Rear Support Brackets
21 - 4 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

Page 1640 of 2889

DODGE RAM 2001 Service Repair Manual DISASSEMBLY
FRONT HOUSING
(1) Shift transmission into Neutral.
(2) If lubricant was not drained out of transmis-
sion during removal, remove drain plug and drain
lubricant.
(3) Inspect drain plug magn

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