2001 DODGE RAM lock

(8) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 54).
Verify bearing is properly seated.
(9) Install fifth gear on shaft and onto bearing
(Fig. 55).
(10) Invert output shaft and set the shaft in Spe-
cial Tool 6310-1 so that fifth gear is seated on the
tool (Fig. 56).
(11) Install first gear bearing on output shaft (Fig.
56). Verify bearing is seated on shaft shoulder and is
properly joined.(12) Install first gear on shaft and over bearing
(Fig. 57). Verify bearing synchro cone is facing up as
shown.
Fig. 54 Fifth Gear Bearing
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 55 Fifth Gear
1 - FIFTH GEAR
2 - BEARING
Fig. 56 First Gear
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - SPECIAL TOOL 6310-1
4 - PRESS BLOCKS
Fig. 57 First Gear
1 - FIRST GEAR
2 - SPECIAL TOOL 6310-1
3 - BEARING
21 - 20 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(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 splines.
(32) Install thickestnew3-4 synchro hub snap
ring (Fig. 73) that will fit in shaft groove. Verify snap
ring is seated in groove.
NOTE: Snap rings are available in thicknesses from
2.00 - 2.30 mm (0.078 - 0.090 in.).(33) Install output shaft bearing.
(34) Install output shaft bearing snap ring with
heavy duty snap ring pliers (Fig. 74). Verify snap
ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
(35) Verify position of synchro sleeves before pro-
ceeding (Fig. 75). Grooved side of 3-4 sleeve must be
facing forward. First gear side of 1-2 sleeve must be
facing first gear. Tapered side of fifth-reverse sleeve
must be facing forward.
REVERSE IDLER ASSEMBLY
(1) Lubricate idler components with gear lube.
(2) Slide idler gear bearing on shaft (Fig. 76).
Bearing fits either way on shaft.
(3) Slide gear onto shaft. Side of gear with recess
goes to rear (Fig. 76).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 76). Petroleum jelly can be used to
hold ball in place if desired.
(5) Slide thrust rear thrust washer onto shaft and
over lock ball (Fig. 77).
(6) Install snap ring in groove at rear of shaft (Fig.
77).
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
Fig. 72 Press 3-4 Synchro On Output Shaft
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 73 3-4 Synchro Hub Snap Ring
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 74 Output Shaft Bearing Snap
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
BR/BEMANUAL - NV3500 21 - 25
MANUAL - NV3500 (Continued)

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 SYNCHRO SLEEVE
8 - 3-4 SYNCHRO SLEEVE
Fig. 76 Idler Gear And Bearing
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFTFig. 77 Idler Gear Rear Thrust Washer
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
21 - 26 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(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)

(2) Install 3-4 shift fork in synchro sleeve (Fig. 98).
Verify groove in fork arm is aligned with grooves in
1-2 and fifth-reverse fork arms as shown.
(3) Slide shift shaft through 3-4 shift fork (Fig.
99)with shaft detent notches to the rear.
(4) Assemble shift shaft shift lever and bushing
(Fig. 100). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 101).(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
102).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 103).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
Fig. 98 3-4 Shift Fork
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 99 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 100 Shift Shaft Lever And Bushing
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 101 Install Shift Shaft Lever And Bushing
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
21 - 34 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-
mission will have to be disassembled again to cor-
rect shaft alignment.
(9) Select correctnewroll pin for shift shaft lever
(Fig. 104). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 105).(11) Seat shaft lever roll pin with pin punch (Fig.
106).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 106).
(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 107).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket after installation
(Fig. 108).
(15) Verify that notches in shift fork arms are
aligned. Realign arms if necessary.
Fig. 102 Inserting Shaft Into Lever Opening
1 - SHIFT SHAFT
Fig. 103 Shift Socket
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 104 Roll Pin Identification
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 105 Roll Pin In Shift Socket
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
BR/BEMANUAL - NV3500 21 - 35
MANUAL - NV3500 (Continued)

FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) If previously removed, install input shaft bear-
ing in front housing bore (Fig. 109). Install snap ring
and use plastic mallet to seat bearing. Bearing goes
in from front side of housing only.
(2) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 109). Large diameter side of
bearing cage goes toward countershaft (Fig. 110).
Small diameter side goes toward bearing race in
housing.(3) Reach into countershaft front bearing with fin-
ger and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
Fig. 106 Shift Shaft Lever Roll
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 107 Roll Pin In Shift Socket
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 108 Seat Shift Socket
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
Fig. 109 Input Shaft Bearing And Countershaft Front
Bearing
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
21 - 36 MANUAL - NV3500BR/BE
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)