2001 DODGE RAM Service Repair Manual

wiper fluid ECO mode lug pattern hood open service schedule manual transmission

Page 1745 of 2889

DODGE RAM 2001 Service Repair Manual and crocus cloth with oil when smoothing/polishing.
Replace the retainer if worn or damaged in any way.
Do not reuse original retainer bolts. Install new bolts
during assembly.
Inspect the countershaf

and crocus cloth with oil when smoothing/polishing.
Replace the retainer if worn or damaged in any way.
Do not reuse original retainer bolts. Install new bolts
during assembly.
Inspect the countershaft and bearings. Replace the
bearings if worn, rough, flat spotted or heat checked.
Check the countershaft gear teeth carefully. Small
nicks, scratches or burrs can be removed with an oil
stone and 400 grit paper wetted with oil. Replace the
shaft if any of the teeth are worn, cracked, broken or
severely chipped.
Be sure to check condition of the countershaft bear-
ing cups. Replace either bearings cup if worn, or
damaged.
Check condition of the mainshaft. Inspect all the
bearing surfaces, splines and threads. Also check con-
dition of the snap ring grooves in the hub area and
the speedometer drive gear teeth. Minor scratches or
burrs can be removed with an oil stone and polished
with crocus cloth. However, replace the shaft if any
surfaces exhibit considerable wear or damage.
Check condition of the gear case and extension or
adapter housing. Be sure the alignment dowels in the
case top surface and in the housing/adapter are tight
and in good condition.
Run a tap through the gear case bolt holes if the
threads need minor cleanup. Helicoil inserts can be
used to repair seriously damaged threaded holes if
necessary.
Be sure all case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. This is
especially important as gaskets are not used in the
transmission. Minor nicks and scratches on the seal-
ing surfaces can be dressed off with a fine tooth file
or oil stone.
Replace the gear case or housing/adapter if cracked
or broken. Do not attempt to repair this type of dam-
age by welding or brazing.
Check condition of the countershaft fifth gear com-
ponents. This includes the shift lug and rail located
in the gear case and the rail bushings.
Inspect the gear and hub assembly. Minor burrs
can be cleaned up with an oil stone. However, the
gear and hub assembly should be replaced if the
teeth or splines are excessively worn, or damaged.
The synchro sleeve should also be replaced if worn or
damaged in any way. Do not reuse synchro struts
that are worn or springs that are collapsed or
severely distorted. Replace worn distorted synchro
parts to avoid shift problems after assembly and
installation.
The shift fork should be inspected for evidence of
wear and distortion. Check fit of the sleeve in the
fork to be sure the two parts fit and work smoothly.
Replace the fork if the roll pin holes are worn over-
size or damaged. Do not attempt to salvage a wornfork. It will cause shift problems later on. Replace
shift fork roll pins if necessary or if doubt exists
about their condition.
The bearings should be examined carefully for
wear, roughness, flat spots, pitting or other damage.
Replace the bearings if necessary.
Inspect the blocker ring and clutch gear. replace
either part if worn or damaged in any way. Also be
sure replacement parts fit properly before proceeding
with assembly.
Examine the 1-2 synchro hub and sleeve for wear
or damage. Replace sleeve and hub if the splines are
worn, chipped or damaged.
Replace the synchro struts if worn, or chipped. Also
replace the springs if collapsed, distorted or broken.
Inspect the mainshaft geartrain components.
Check teeth on all gears, hubs, clutch gears, stop
rings and clutch rings. The teeth must be in good
condition and not worn, cracked or chipped. Replace
any component that exhibits wear or damage.
Examine the synchro stop rings, clutch rings and
clutch gears. Replace any part that exhibits wear,
distortion or damage. Replace the clutch rings if the
friction material is burned, flaking off or worn.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the wash-
ers if worn or the locating pin notches are distorted.
Check condition of the synchro struts and springs.
Replace these parts if worn, cracked or distorted.
ASSEMBLY
NOTE: Gaskets are not used in the transmission.
Use MoparTGasket Maker or equivalent on all gear
case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Place second gear on bench with the synchro
clutch ring up.
(2) Install second gear synchro inner blocker ring
onto second gear (Fig. 53).
(3) Install second gear synchro friction cone over
the blocker ring and onto second gear (Fig. 54).
(4) Install second gear synchro outer blocker ring
over the second gear synchro friction cone. Align one
of the lugs on the outer ring with a lug on the inner
ring (Fig. 55).
(5) Install 1-2 synchro assembly onto the second
gear assembly (Fig. 56).
(6) Reverse assembly on the bench.
21 - 110 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

Page 1746 of 2889

DODGE RAM 2001 Service Repair Manual Fig. 53 Inner Blocker Ring
1 - INNER BLOCKER RING
2 - GEAR
Fig. 54 Friction Cone
1 - LOW AREA
2 - GEAR
3 - HIGH AREA
Fig. 55 Outer Blocker Ring
1 - OUTER BLOCKER RING
2 - LUG
3 - GEAR
Fig. 56 3-4 Sync

Page 1747 of 2889

DODGE RAM 2001 Service Repair Manual (7) Install second gear bearing into second gear
(Fig. 57).
(8) Place completed 1-2 synchro, second gear and
second gear bearing to a shop press with second gear
facing upward.
(9) Install output shaf

Page 1748 of 2889

DODGE RAM 2001 Service Repair Manual (21) Install rear output shaft bearing onto the out-
put shaft with Installer 8228 and a shop press (Fig.
62).
(22) Install anewsnap-ring to hold the rear out-
put bearing onto the output shaft. Selec

Page 1749 of 2889

DODGE RAM 2001 Service Repair Manual Fig. 63 Sixth Gear
1 - 6TH GEAR
2 - 6TH GEAR BEARING
Fig. 64 Sixth Gear Blocker Ring
1 - 6TH GEAR BLOCKER RING
2 - 6TH GEAR FRICTION CONE
Fig. 65 Output Shaft Guide
1 - GUIDE 8235
2 - OUTPUT SHAFT
Fig

Page 1750 of 2889

DODGE RAM 2001 Service Repair Manual (32) Press pocket bearing the remainder of the
way onto the output shaft using Guide 8235 and a
shop press (Fig. 67).
(33) Install anewsnap-ring to hold the output
shaft pocket bearing onto the output

Page 1751 of 2889

DODGE RAM 2001 Service Repair Manual (20) Press countershaft into sixth gear (Fig. 73).
(21) Place fifth countershaft gear into the shop
press.
Fig. 70 3-4 Synchro Assembly
1 - SYNCHRO
2 - GEAR
Fig. 71 Countershaft into 3-4 Synchro
1 - C

Page 1752 of 2889

DODGE RAM 2001 Service Repair Manual (22) Install countershaft into the fifth countershaft
gear and press countershaft into fifth gear (Fig. 74).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.

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