2001 DODGE RAM light

(7) Install rear housing onto geartrain (Fig. 92)
and verify bearing retainer pilot stud is in correct
bolt hole in housing. Be sure countershaft and output
shaft bearings are aligned in housing and on counter-
shaft.
NOTE: It may be necessary to lift upward on coun-
tershaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
(9) Apply Mopar Gasket Maker or equivalent to
housing bolt threads, bolt shanks and under bolt
heads (Fig. 93).
(10) Start first two bolts in retainer (Fig. 94). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 94).
(12) Tighten all three retainer bolts to 30-35 N´m
(22-26 ft. lbs.).
ADAPTER HOUSING - 4WD
(1) Install rear bearing in adapter housing. Use
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 95).
Fig. 92 Rear Housing - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 93 Housing Bolts
1 - MOPAR GASKET MAKER (OR LOCTITE 518)
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 94 Pilot Stud Tool And Retainer Bolts - 2WD
1 - BEARING RETAINER BOLT
2 - PIN 8120
21 - 32 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(3) Apply Mopar Gasket Maker or equivalent to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 93).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 91).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 91).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 91).
(8) Install adapter housing on geartrain.
(9) Install rear bearing snap ring on output shaft
(Fig. 96).
(10) Lubricate lip of new rear seal (Fig. 97) with
MopartDoor Ease, or transmission fluid.
(11) Installnewrear seal in adapter housing bore
with Installer C-3860-A. Verify seal is seated in hous-
ing bore (Fig. 97).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Verify that all synchro sleeves are in Neutral
position (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position for reassembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
Fig. 95 Adapter Housing - 4WD
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
Fig. 96 Rear Bearing Snap Ring - 4WD
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 97 Rear Seal
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
BR/BEMANUAL - NV3500 21 - 33
MANUAL - NV3500 (Continued)

(5) Apply 1/8 in. wide bead of MopartGasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 111).
(6) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(9) Place transmission in horizontal position.
(10) Apply MopartGasket Maker or equivalent, to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 112).
(11) Install and start housing attaching bolts by
hand (Fig. 112). Then tighten bolts to 34 N´m (25 ft.
lbs.).
(12) Install shift shaft bushing lock bolt (Fig. 113).
Apply Mopar Gasket Maker or equivalent to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubricate then install shift shaft detent
plunger in housing bore (Fig. 114). Lubricate plunger
with petroleum jelly or gear lubricant. Verify plunger
is fully seated in detent notch in shift shaft.
(14) Install detent spring inside plunger (Fig. 114).
(15) Install detent plug in end of Installer 8123.
Position plug on detent spring and compress spring
until detent plug pilots in detent plunger bore. Drive
detent plug into transmission case until plug seats.
(16) Install backup light switch (Fig. 115).
Fig. 110 Countershaft Front Bearing
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 111 Seal Front/Rear Housings
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 112 Housing Bolts
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
BR/BEMANUAL - NV3500 21 - 37
MANUAL - NV3500 (Continued)

(17) Install input shaft snap ring (Fig. 116).
(18) Installnewoil seal in front bearing retainer
with Installer 6448 (Fig. 117).
(19) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
118).
(20) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
119). Verify bolt holes are aligned before seating
retainer.
CAUTION: Be sure sealer does not get into the oil
feed hole in the transmission case or bearing
retainer.
Fig. 113 Shift Shaft Bushing Lock Bolt
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 114 Shift Shaft Detent Plunger
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
Fig. 115 Backup Light Switch
1 - BACKUP LIGHT SWITCH
Fig. 116 Shaft Snap Ring - Typical
1 - INPUT SHAFT SNAP RING
Fig. 117 Oil Seal In Front Bearing Retainer
1 - INSTALLER 6448
2 - FRONT BEARING RETAINER
21 - 38 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(5) Fill transmission to bottom edge of fill plug
hole with Mopar Transmission Lubricant.
(6) Install and tighten fill plug to 34 N´m (25 ft.
lbs.).
(7) Check transmission vent. Be sure vent is open
and not restricted.
INSTALLATION
NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.
Make sure transmission front housing mounting
surface is clean. Before installation apply light coat
of Mopar high temperature bearing grease to contact
surfaces of following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(1) Support and secure transmission to jack with
safety chains.
(2) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(3) Install and tighten transmission bolts to 54-61
N´m (40-45 ft. lbs.). Be sure front housing is fully
seated before tightening bolts. Install front dust
cover after all bolts are tightened.
(4) Fill transmission with Mopar lubricant. Correct
fill level is to bottom edge of fill plug hole.
(5) Connect backup lamp switch wires.(6) Connect transmission harnesses to clips on
case.
(7) Install crossmember. Tighten crossmember-to-
frame bolts to 68 N´m (50 ft. lbs.).
(8) Tighten crossmember-to-transmission insulator
nuts to 68 N´m (50 ft. lbs.).
(9) Install slave cylinder. Tighten cylinder nuts to
23 N´m (200 in. lbs.).
(10) Remove jack used to support transmission.
(11) Install strut bolts/nuts, if removed. Also
install oil filter if removal was necessary.
(12) Install and connect exhaust system. Align
exhaust components before tightening clamp and
bracket bolts and nuts. Be sure exhaust components
are clear of all chassis and driveline components.
TWO WHEEL DRIVE
(1) Align and install propeller shaft.
(2) Verify that all linkage components, hoses and
electrical wires have been connected.
(3) Remove any remaining support stands and
lower vehicle.
(4) Install crankshaft position sensor.
(5) Connect battery negative cable.
(6) Install shift tower and lever assembly. Tighten
shift tower bolts to 7-10 N´m (5-7 ft. lbs.).
(7) Install the shift lever extension onto the shift
tower and lever assembly.
(8) Install shift boot and bezel.
FOUR WHEEL DRIVE
(1) Install transfer case. Align and position trans-
fer case with transmission jack or aid of helper.
(2) Install and tighten transfer case attaching nuts
to 47 N´m (35 ft. lbs.).
(3) Install and connect transfer case shift linkage.
(4) Align and install front and rear propeller
shafts.
(5) Verify that all linkage components, hoses and
electrical wires have been connected.
(6) Check transfer case fluid level. Add Mopar
Dexron II, or ATF Plus if necessary. Correct level is
to edge of fill plug hole. Be sure transfer case is level
before checking or adding fluid.
(7) Check and adjust transfer case shift linkage if
necessary.
(8) Install transfer case skid plate, if equipped.
(9) Install crankshaft position sensor.
(10) Remove any remaining support stands and
lower vehicle.
(11) Connect battery negative cable.
(12) Install shift tower and lever assembly. Tighten
shift tower bolts to 7-10 N´m (5-7 ft. lbs.).
(13) Install the shift lever extension onto the shift
tower and lever assembly.
(14) Install shift boot and bezel.
Fig. 122 Shift Tower Bolts
1 - SHIFT TOWER AND LEVER ASSEMBLY
21 - 40 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

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 screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
Fig. 4 NV4500 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
BR/BEMANUAL - NV4500 21 - 47
MANUAL - NV4500 (Continued)

(18) Remove bolts attaching mainshaft rear bear-
ing plate to gear case and remove fifth gear plate end
play shims and bearing cup (Fig. 18).
FRONT RETAINER
(1) Remove front retainer bolts (Fig. 19). Discard
retainer bolts. They should not be reused.
(2) Remove retainer by lightly tapping it back and
forth with plastic mallet. Then rock retainer back
and forth by hand to work it out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
(3) Remove seal from front retainer (Fig. 20). Col-
lapse one side of seal then pry it out with pry tool.(4) To remove front retainer bearing cup, assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
21).
(5) Insert Puller Jaws 6453-1 in puller flange (Fig.
21). Narrow lip of puller jaws will go under bearing
cup.
(6) Install Disc C-4487-1 into bearing retainer on
heavy duty transmissions for Insert 6453-2 to rest
upon.
Fig. 18 Mainshaft Fifth Gear Bearing Plate, Bearing
Shims, And Rear Bearing Cup
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 19 Front Bearing Retainer
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
Fig. 20 Bearing Retainer Seal
1 - SEAL
2 - FRONT BEARING RETAINER
Fig. 21 Puller Rods, Flange And Jaws
1 - RODS 6444-4
2 - FLANGE 6444-1
3 - JAWS 6453-1
21 - 52 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 27).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 28).
(4) Roll gear case onto left side (Fig. 29).
(5) To remove mainshaft assembly (Fig. 29) lift
front end of mainshaft slightly.
NOTE: Handling mainshaft carfully because gears
are lose on the mainshaft.
(6) Grasp mainshaft rear splines, then turn spline
end of mainshaft counterclockwise to rotate shaft and
geartrain out of case. Tilt mainshaft outward and
removed from case.
Fig. 25 Pilot Bearing
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 26 Front Bearing Puller
1 - PULLER 6444
2 - RODS 6444-6
3 - JAWS 6447
4 - COLLAR 6444-8
5 - FLANGE 6444-1
6 - DRIVE GEAR
Fig. 27 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 28 Fourth Gear Clutch Gear Stop Ring
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
21 - 54 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)