2001 DODGE RAM light

(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 40).
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 41). A small pin punch can be mod-
ified by putting a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 41).(4) Remove shift lug rail.
MAINSHAFT
NOTE: Not all of the mainshaft gear and synchro
components are a one-way fit. Some gear and syn-
chro components can be installed backwards. Paint
or scriber gear and synchro components for instal-
lation reference. Then stack geartrain parts in order
of removal to avoid incorrect assembly.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Remove 3-4 synchro hub, third gear stop ring
and third gear as an assembly (Fig. 42).
Fig. 40 Countershaft Front Bearing Cup
1 - REMOVER 6454
2 - HANDLE C-4171
Fig. 41 Shift Lug Roll Pin
1 - PUNCH
2 - 30É BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
Fig. 42 Third Gear, Stop Ring, And 3-4 Hub
1 - THIRD GEAR
2 - THIRD GEAR STOP RING
3 - 3-4 SYNCHRO HUB
21 - 58 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(10) Install assembled second gear clutch cone and
rings on mainshaft and in 1-2 synchro hub (Fig. 86).
(11) Install snap ring that secures second gear
clutch cone on mainshaft (Fig. 87). Use narrow blade
screwdriver to work snap ring into hub groove as
shown. Verify snap ring is seated in mainshaft
groove.NOTE: If snap ring will not fit in groove, clutch cone
is slightly misaligned.
Fig. 84 1-2 Synchro Snap Ring
1 - SYNCHRO SNAP RING
2 - 1-2 SYNCHRO ASSEMBLY
3 - MAINSHAFT HUB
Fig. 85 Second Gear Clutch Cone, Clutch Ring And
Stop Ring
1 - STOP RING
2 - CLUTCH RING
3 - CLUTCH CONE
Fig. 86 Second Gear Clutch Cone, Clutch Ring And
Stop Ring
1 - CLUTCH CONE
2 - STOP RING
3 - CLUTCH RING
Fig. 87 Second Gear Clutch Cone Snap Ring
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
4 - SECOND GEAR CLUTCH CONE
BR/BEMANUAL - NV4500 21 - 71
MANUAL - NV4500 (Continued)

(37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 105).
(38) Install fourth gear clutch gear in stop ring
(Fig. 106).
(39) Roll gear case onto its left side.
(40) Grip mainshaft at pilot bearing hub and just
behind reverse gear. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
(41) Continue holding front of shaft but switch
grip at rear to shaft output splines. Lift mainshaft
assembly slightly, align gears and seat assembly in
case.
(42) Set transmission case upright (Fig. 107).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 108). Use plenty of petroleum jelly to hold bear-
ing in place.
(44) Check alignment and mesh of mainshaft
gears. If gears are not aligned, roll case on side and
realign shaft and gears in case.DRIVE GEAR AND RETAINER
(1) Install bearing on drive gear with Installer
6448 (Fig. 109).
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear
rearward until mainshaft hub is seated in pilot bear-
ing.
(4) Install bearing cup in front retainer with Han-
dle C-4171 and Installer C-4308 (Fig. 110).
(5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 111). Use one or two wood
blocks to support retainer as shown. Lubricate seal
lip with petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover.
Fig. 105 Fourth gear Stop Ring
1 - 3-4 SYNCHRO SLEEVE
2 - FOURTH SPEED STOP RING
Fig. 106 Fourth gear Clutch Gear
1 - FOURTH SPEED CLUTCH GEAR
Fig. 107 Mainshaft And Geartrain In Case
1 - MAINSHAFT AND GEARTRAIN ASSEMBLY
2 - FOURTH SPEED CLUTCH GEAR
Fig. 108 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
21 - 76 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

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.
Befor installation apply light coat of Mopar high
temperature bearing grease to contact surfaces of fol-
lowing 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) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(2) Mount transmission on jack and position trans-
mission under vehicle.
(3) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(4) Move transmission forward and start input
shaft in release bearing, clutch disc and pilot bush-
ing.
(5) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(6) Install and tighten transmission-to-clutch hous-
ing bolts to 108 N´m (80 ft. lbs.).
(7) Install transmission mount on transmission or
rear crossmember.
(8) Install rear crossmember.
(9) Remove transmission jack and engine support
fixture.
(10) Position transmission harness wires in clips
on shift cover.
(11) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(12) Connect speed sensor and backup light switch
wires.
TWO WHEEL DRIVE
(1) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(2) Align and install propeller shaft.
(3) Lower vehicle.
(4) Clean the mating surfaces of shift tower, isola-
tor plate, and shift cover with suitable wax and
grease remover.
(5) Apply Mopar Gasket Maker, or equivalent, to
the sealing surface of the shift cover. Do not over
apply sealant.(6) Install the isolator plate onto the shift cover,
metal side down.
(7) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(8) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
(9) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(10) Install the shift lever extension onto the shift
tower and lever assembly.
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install transfer case shift mechanism on trans-
mission.
(2) Install transfer case on transmission jack.
Secure transfer case to jack with safety chains.
(3) Raise jack and align transfer case input gear
with transmission mainshaft.
(4) Move transfer case forward and seat it on
adapter.
(5) Install and tighten transfer case attaching
nuts. Tighten nuts to 41-47 N´m (30-35 ft. lbs.) if
case has 3/8 studs, or 30-41 N´m (22-30 ft. lbs.) if
case has 5/16 studs.
(6) Install transfer case shift mechanism to side of
transfer case.
(7) Connect transfer case shift lever to range lever
on transfer case.
(8) Align and connect propeller shafts.
(9) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(10) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.) torque.
(11) Install exhaust system components.
(12) Lower vehicle.
(13) Clean the mating surfaces of shift tower, iso-
lator plate, and shift cover with suitable wax and
grease remover.
(14) Apply Mopar Gasket Maker, or equivalent, to
the sealing surface of the shift cover. Do not over
apply sealant.
(15) Install the isolator plate onto the shift cover,
metal side down.
(16) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(17) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
21 - 82 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

ADAPTER HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Mark the propeller shafts and yokes for instal-
lation reference and remove the shafts.
(3) Support transmission with a transmission jack.
(4) Remove engine rear support. Refer to Group 9
Engine for procedures.
(5) Remove transfer case.
(6) Remove adapter housing seal with a pry tool or
slide hammer mounted screw (Fig. 128).
INSTALLATION
(1) Install adapter housing seal with Installer
C-3860-A and Handle C-4171.
(2) Install transfer case.
(3) Install propeller shafts with reference macks
aligned.
(4) Fill transfer case and transmission to proper
level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the propeller shaft and yoke for installa-
tion reference.
(3) Remove the propeller shaft.
(4) On light duty 4X2 vehicles, remove extension
housing seal (Fig. 129) using Remover C-3985-B.
(5) On heavy duty 4X2 vehicles, remove extension
housing seal with a pry tool or a slide hammer
mounted screw.(6) On light duty transmissions, remove the exten-
sion housing bushing with Remover 6957.
(7) On heavy duty transmissions, remove the
extension housing bushing with Remover 8155.
INSTALLATION
(1) On light duty transmissions, install housing
bushing with Installer 6951 and Handle C-4171 (Fig.
130).
(2) On heavy duty transmissions, install housing
bushing with Installer 8156 and Handle C-4171.
(3) On light duty transmissions, install housing
seal with Installer C-3972-A and Handle C-4171 (Fig.
131).
(4) On heavy duty transmissions, install housing
seal with Installer 8154 and Handle C-4171.
(5) Install propeller shaft with reference marks
aligned.
(6) Check and fill transmission.
Fig. 128 Adapter Housing - 4WD
1 - ADAPTER HOUSING
2 - SEAL
Fig. 129 Extension Housing - 2WD
1 - EXTENSION HOUSING
2 - SEAL
Fig. 130 Extension Housing Bushing
1 - HANDLE
2 - INSTALLER
3 - EXTENSION HOUSING
BR/BEMANUAL - NV4500 21 - 87

EXPANSION PLUG
The expansion plugs at the rear of the shift rail
bores (Fig. 136) can be replaced if loose and/or leak-
ing.
(1) Drill 6 mm (1/4 in.) diameter hole in center of
each plug to be removed.
(2) Pry plug out of cover with tapered punch.
(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of sealer to outer edge of
each new plug. Use Mopartsilicone adhesive/sealer,
or equivalent.
(2) Position each new plug in bore and tap into
place with hammer and suitable size punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab.
(2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift cover and gear
case with wax and grease remover.
(2) Apply MopartSilicone Sealer, or equivalent, to
sealing surface of shift cover or gear case. Do not
over±apply sealer material. Excess can be squeezed
into gear case and could block lubricant feed holes in
time.
(3) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(4) Verify that the shift fork pads (Fig. 137) are
properly and securely positioned on the fifth-reverse
fork
(5) Verify that 1-2 and 3-4 synchro sleeves are in
neutral position. Also verify that forks in shift cover
are in neutral position.
(6) Align and install shift cover. If cover will not
seat, it is either not aligned on gear case dowels, or
shift forks are not aligned with sleeves and shift lug.
(7) Apply MopartLock N' Seal, or equivalent, to
threads of shift cover bolts.
(8) Install and tighten shift cover bolts to 27-31
N´m (216-276 in. lbs.).
(9) Install backup lamp switch and gasket in cover.
Apply sealer to switch threads before installation and
tighten switch to 22-34 N´m (193-265 in. lbs.).
(10) Install vent assembly, if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
(11) Install transmission.
Fig. 135 Shift Fork Pad Locations
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
Fig. 136 Expansion Plug Location
1 - EXPANSION PLUGS
Fig. 137 Fifth-Reverse Shift Fork Pads
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
BR/BEMANUAL - NV4500 21 - 89
SHIFT MECHANISM (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
NOTE: Use a heavy duty scissors style transmis-
sion jack for remove of the transmission.
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.(4) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(5) Remove the shift tower and isolator plate from
the transmission gear case.
(6) Raise and support vehicle.
(7) Remove skid plate, if equipped.
(8) Mark propeller shaft/shafts and axle yokes for
installation reference.
(9) Remove propeller shaft.
(10) Disconnect and remove exhaust system as
necessary.
(11) Disconnect wires at backup light switch.
(12) Support engine with adjustable safety stand
and wood block.
(13) If transmission is to be disassembled for
repair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission (Fig. 4).
(14) Remove clutch slave cylinder splash shield, if
equipped.
(15) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(16) Remove wire harness from clips on transmis-
sion.
TWO WHEEL DRIVE
(1) Remove bolts/nuts mounting transmission to
the rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove transmission clutch housing bolts at
the engine block.
(5) Slide transmission and jack rearward until
input shaft clears clutch disc and pressure plate.
(6) Lower transmission jack and remove transmis-
sion from under vehicle.
Fig. 4 NV5600 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
21 - 94 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(7) Remove output shaft nut with Wrench 8226 on
the shaft nut and Socket 6993 or 6984 to hold the
shaft (Fig. 22). Discard output shaft nut from the
output shaft.
NOTE: If necessary strike the flat side area of
Wrench 8226 with a hammer to break the nut loose.
(8) Remove output shaft ball bearing assembly and
reverse thrust washer from the output shaft (Fig.
23).(9) Remove reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring and reverse
gear bearing (Fig. 24).
(10) Remove reverse gear bearing sleeve from the
output shaft (Fig. 25).
NOTE: If necessary heat the sleeve slightly with a
heat gun. Do not use a torch to heat the sleeve or
damage to the output shaft may occur.
(11) Remove roll-pin securing the reverse shift fork
to the reverse shift rail. Use a 6mm (7/32 inch)
punch and hammer.
(12) Remove reverse shift fork and synchronizer as
an assembly from the reverse shift rail and the out-
put shaft (Fig. 26).
Fig. 22 Output Shaft Nut
1 - WRENCH 8226
2 - SOCKET 6993
Fig. 23 INSTALL OUTPUT SHAFT BEARING
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
Fig. 24 REVERSE GEAR COMPONENTS
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
21 - 100 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)