2001 DODGE RAM lock

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 Synchro Assembly
1 - SYNCHRO
2 - GEAR
BR/BEMANUAL - NV5600 21 - 111
MANUAL - NV5600 (Continued)

(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 shaft into the second gear 1-2
synchro assembly with the front of the output shaft
facing upward (Fig. 58).
(10) Press the output shaft into position.(11) Place first gear on bench with the synchro
clutch ring up.
(12) Install first gear synchro inner blocker ring
onto first gear (Fig. 53).
(13) Install first gear synchro friction cone over the
blocker ring and onto first gear (Fig. 54).
(14) Install first gear synchro outer blocker ring
over the first gear synchro friction cone. Align one of
the lugs on the outer ring with a lug on the inner
ring (Fig. 55).
(15) Reverse the output shaft in the press.
(16) Install first gear bearing sleeve onto the out-
put shaft.
(17) Install first gear bearing sleeve the remainder
of the way onto the output shaft using Installer 8228
and a shop press (Fig. 59).
(18) Install first gear and blocker assembly onto
the output shaft (Fig. 60).
(19) Install first gear bearing over the output shaft
and into first gear.
(20) Install output shaft thrust washer onto the
output shaft (Fig. 61).
Fig. 57 Second Gear Bearing
1 - BEARING
2 - GEAR
Fig. 58 Output Shaft Into 1-2 Synchro
1 - OUTPUT SHAFT
2 - 1-2 SYNCHRO
3 - SECOND GEAR
Fig. 59 First Gear Bearing Sleeve
1 - INSTALLER 8228
2 - FIRST GEAR BEARING SLEEVE
21 - 112 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(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. Select and install
the thickest snap-ring which will fit into the groove.
(23) Reverse output shaft in the Fixture 8227 and
support the shaft with press blocks under first gear.
(24) Install sixth gear bearing onto the output
shaft.
(25) Install sixth gear onto the output shaft and
over the sixth gear bearing (Fig. 63).
(26) Install the sixth gear friction cone onto sixth
gear.
(27) Install sixth gear blocker ring over the sixth
gear friction cone (Fig. 64).
(28) Install Guide 8235 onto the end of the output
shaft (Fig. 65).
(29) Install 5-6 synchro over Guide 8235 and onto
the output shaft (Fig. 66).
(30) Press 5-6 synchro onto the output shaft with
Installer 8156 and a shop press.
(31) Install output shaft pocket bearing onto the
output shaft.
Fig. 60 First Gear And Blocker Assembly
1 - OUTPUT SHAFT
2 - 1ST GEAR AND BLOCKER ASSEMBLY
Fig. 61 Output Shaft Thrust Washer
1 - OUTPUT SHAFT
2 - OUTPUT SHAFT THRUST WASHER
Fig. 62 Rear Output Shaft Bearing
1 - INSTALLER 8228
2 - REAR OUTPUT SHAFT BEARING
BR/BEMANUAL - NV5600 21 - 113
MANUAL - NV5600 (Continued)

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. 66 5-6 Synchro
1 - INSTALLER 8156
2 - 5-6 SYNCHRO
21 - 114 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(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 shaft.
COUNTERSHAFT
(1) Place third countershaft gear on the bench
with the synchro clutch ring up.
(2) Install third countershaft gear friction cone
onto third gear (Fig. 68).
(3) Install third countershaft gear blocker ring
onto the friction cone (Fig. 69).
(4) Install 3-4 synchro assembly onto the blocker
ring/gear assembly (Fig. 70).
(5) Reverse the assembly on the bench.
(6) Install third countershaft gear bearing into the
third countershaft gear.
(7) Install 2-3 thrust washer onto the countershaft.
(8) Place third gear/3-4 synchro assembly in a shop
press.
(9) Install countershaft through the third gear/3-4
synchro assembly.
(10) Press countershaft into the 3-4 synchro
assembly (Fig. 71).
(11) Install fourth countershaft gear bearing sleeve
onto the output shaft.
(12) Press fourth countershaft bearing sleeve onto
the countershaft with Installer 8228 and a shop
press.(13) Place fourth countershaft gear on the bench
with the synchro clutch ring up.
(14) Install fourth countershaft gear friction cone
onto fourth countershaft gear (Fig. 68).
(15) Install fourth countershaft gear blocker ring
onto the friction cone (Fig. 69).
(16) Install fourth countershaft gear bearing into
the fourth countershaft gear.
(17) Place sixth countershaft gear in the shop
press.
(18) Position fourth countershaft gear assembly
onto the sixth countershaft gear (Fig. 72).
(19) Install countershaft into the fourth/sixth coun-
tershaft gear assembly in the shop press.
Fig. 67 Output Shaft Pocket Bearing
1 - GUIDE 8235
2 - POCKET BEARING
Fig. 68 Friction Cone Onto Gear
1 - FRICTION CONE
2 - GEAR
3 - CLUTCH RING
Fig. 69 Blocker Ring Onto Friction Cone
1 - BLOCKER RING
2 - GEAR
3 - FRICTION CONE
BR/BEMANUAL - NV5600 21 - 115
MANUAL - NV5600 (Continued)

GEARTRAIN
(1) Install input shaft into Support Stand 8246.
(2) Install fifth gear friction cone onto the input
shaft.
(3) Install fifth gear blocker ring onto the fifth
gear friction cone.
(4) Install output shaft into the input shaft (Fig.
79).
(5) Install countershaft into the Support Stand
8246 and verify that all gears are meshed with their
mates on the mainshaft (Fig. 80).
(6) Install Fixture 8232 to the output shaft and
the countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5±6 synchro
together during the remainder of the installation pro-
cedure.(8) Attach and engine crane or equivalent to Fix-
ture 8232 and move the geartrain from the Support
Stand 8246 to the clutch housing (Fig. 81).
(9) Install shift forks and rails onto the geartrain
(Fig. 82).
NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) Install geartrain and shift rails into the clutch
housing. Lower the geartrain and rails into the hous-
ing slowly while guiding input shaft through input
shaft seal. Avoid any binds on the shift rails, forks
and synchros as the rails enter their bushings.
CAUTION: Do not damage input shaft seal with the
input shaft splines.
Fig. 79 Install Output Shaft to Input Shaft
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND 8246
Fig. 80 Countershaft to Mainshaft
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND 8246
BR/BEMANUAL - NV5600 21 - 119
MANUAL - NV5600 (Continued)

(6) Install anewinput shaft seal into the input
shaft retainer with Installer C-4965.
(7) Install input shaft oil guide with C-3972-A and
Handle C-4171.
(8) Apply sealer to the input shaft retainer and
install retainer onto the clutch housing. Install bolts
and tighten to 28 N´m (20 ft.lbs.).
REVERSE GEAR
(1) Install reverse shift fork and synchronizer as
an assembly onto the reverse shift rail and output
shaft (Fig. 88).
NOTE: Raised square shoulder and snap-ring on
the synchro face the case.
(2) Install roll-pin securing the reverse shift fork
to the reverse shift rail with 6mm (7/32 in) punch
and a hammer.
(3) Install reverse gear bearing sleeve onto the
output shaft with Installer 6446 if necessary (Fig.
89).
(4) Install reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring, and reverse
gear bearing (Fig. 90).
(5) Install output shaft ball bearing assembly and
reverse thrust washer onto the output shaft (Fig. 91).
NOTE: Raised shoulder on thrust washer faces
away from the reverse gear.(6) Install anewoutput shaft nut onto the ouput
shaft.
(7) With Wrench 8226 on the output shaft nut and
Socket 6993 or 6984 holding the output shaft, tighten
the nut to 339 N´m (250 ft.lbs.).
Fig. 87 Measure Countershaft End-Play
1 - EXTENSION ROD 8161
2 - DIAL INDICATOR C-3339
3 - COUNTERSHAFT
Fig. 88 Reverse Shift Fork and Synchro
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 89 Reverse Bearing Sleeve
1 - REVERSE GEAR BEARING SLEEVE
21 - 122 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(8) Stake nut into the slot in the output shaft with
a 9mm (5/16 in.) punch.(9) Press countershaft reverse gear into the sleeve
with a shop press.
(10) Install reverse countershaft rear bearing onto
the countershaft reverse gear assembly with Installer
C-4652 and Handle C-4171.
(11) Install reverse idler gear rear bearing, bearing
spacer, front bearing, and front thrust washer onto
the idler gear shaft.
(12) Install idler and reverse countershaft gears
together (Fig. 92).
(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 93).
Fig. 90 Reverse Gear Components
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
Fig. 91 Output Shaft Bearing and Thrust Washer
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
Fig. 92 Reverse Idler and Countershaft Gears
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 93 Crossover Cam Rollers and Pin
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
BR/BEMANUAL - NV5600 21 - 123
MANUAL - NV5600 (Continued)