2001 DODGE RAM Service Repair Manual

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Page 1657 of 2889

DODGE RAM 2001 Service Repair Manual (21) Install second gear needle bearing on shaft
(Fig. 63).
(22) Install second gear onto shaft and bearing
(Fig. 64). Verify second gear is seated on synchro
components.(23) Install two-piece thrust

Page 1658 of 2889

DODGE RAM 2001 Service Repair Manual (24) Start retaining ring around two-piece thrust
washer (Fig. 66). Verify locating dimple is between
thrust washer halves.
(25) Seat thrust washer retaining ring with plastic
mallet (Fig. 67).
Fig. 6

Page 1659 of 2889

DODGE RAM 2001 Service Repair Manual (26) Install third gear needle bearing on shaft (Fig.
68).
(27) Install third gear on shaft and bearing (Fig.
69).
(28) Install third speed synchro ring on third gear
(Fig. 70).
(29) Assemble 3-4 sync

Page 1660 of 2889

DODGE RAM 2001 Service Repair Manual (31) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 72). Ver-
ify tool presses on hub as close to output shaft as
possible but does not contact the shaft spl

Page 1661 of 2889

DODGE RAM 2001 Service Repair Manual Fig. 75 Synchro Sleeve Locations
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCH

Page 1662 of 2889

DODGE RAM 2001 Service Repair Manual (8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 78).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 78). Verify

(8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 78).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 78). Verify snap
ring is seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/
BEARINGS
(1) Inspect shift shaft bushing and bearing for
damage.
(2) If necessary, the shift shaft bushing can be
replaced as follows:
(a) Locate a bolt that will thread into the bush-
ing without great effort.
(b) Thread the bolt into the bushing, allowing
the bolt to make its own threads in the bushing.
(c) Attach a slide hammer or suitable puller to
the bolt and remove bushing.
(d) Use the short end of Installer 8119 to install
the new bushing.
(e) Bushing is correctly installed if flush with
the transmission case.(3) If necessary, the shift shaft bearing can be
replaced as follows:
(a) Locate a bolt that will thread into the bear-
ing without great effort.
(b) Thread the bolt into the bearing as much as
possible.
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) Bearing is correctly installed if flush with the
transmission case.
(4) Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) If necessary, the detent plunger bushings can
be replaced as follows:
(a) Using the long end of Installer 8119, drive
the detent bushings through the outer case and
into the shift shaft bore.
(b) Remove the bushings from the shift shaft
bore.
(c) Install a new detent plunger bushing on the
long end of Installer 8118.
(d) Start bushing in the detent plunger bore in
the case.
(e) Drive bushing into the bore until the tool
contacts the transmission case.
(f) Install a new detent plunger bushing on the
short end of Installer 8118.
(g) Start the bushing in the detent plunger bore
in the case.
(h) Drive bushing into the bore until the tool
contacts the transmission case.
GEARTRAIN ASSEMBLY
(1) Install Adapter 6747-1A on input shaft hub of
Fixture 6747 (Fig. 79). Then install Adapter 6747-2B
on front bearing hub of countershaft. Be sure the
shoulder is seated against the countershaft.
(2) Install input shaft in fixture tool. Make sure
Adapter Tool 6747-1A is positioned under shaft as
shown (Fig. 80).
(3) Install pilot bearing in input shaft (Fig. 80).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
Fig. 78 Idler Gear And Shaft Assembly
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
BR/BEMANUAL - NV3500 21 - 27
MANUAL - NV3500 (Continued)

Page 1663 of 2889

DODGE RAM 2001 Service Repair Manual (4) Install fourth gear synchro ring on input shaft
(Fig. 81).
(5) Adjust height of idler gear pedestal on assem-
bly fixture (Fig. 82). Start with a basic height of 18.4
cm (7-1/4 in.). Final adjustm

Page 1664 of 2889

DODGE RAM 2001 Service Repair Manual (6) Install assembled output shaft and geartrain in
input shaft (Fig. 83). Carefully rotate output shaft
until the 3-4 synchro ring seats in synchro hub and
sleeve.
(7) Install Adapter 6747-2B on fron

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