2002 DODGE RAM clutch

(22) Install Puller 6444 on the puller rods and
secure with nuts.
(23) Hold hex portion of Puller 6444 a wrench (Fig.
57) and tighten screw.
(24) Remove bearing puller tools and rear main-
shaft bearing from output shaft.
(25) Remove reverse gear thrust washer (Fig. 58).
(26) Remove reverse gear and synchro components
as assembly (Fig. 59). Do not disassemble synchro
components unless they are damaged. If synchro
sleeve or struts require service, mark position of
sleeve on hub before removal. Correct sleeve position
is important as sleeve can be installed backwards
causing shift problems.(27) Remove reverse gear bearing assembly from
mainshaft (Fig. 59).
(28) Remove reverse gear bearing spacer from
mainshaft (Fig. 60).
(29) Remove reverse clutch gear snap ring (Fig.
60). Tension of this snap ring is considerable. Heavy
duty snap ring pliers will be required to spread the
ring far enough to remove it.
Fig. 56 Mainshaft Rear Bearing Puller
1 - REAR BEARING
2 - FLANGE 6444-1
3 - JAW 6445
4 - COLLAR 6444-85 - MAINSHAFT
6 - PULLER 6444
7 - RODS 6443-3 OR 6444-4
8 - JAW 6445
21 - 18 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(30) Remove reverse clutch gear (Fig. 61).
(31) Remove first gear from bearing and mainshaft
(Fig. 62).
(32) Remove first gear bearing from mainshaft
(Fig. 63).
Fig. 57 Mainshaft Rear Bearing
1 - JAWS 6445
2 - COLLAR 6444-8
3 - FLANGE 6444-1
4 - MAINSHAFT
5 - PULLER 6444
6 - TIGHTENING WRENCH
7 - HOLDING WRENCH
8 - RODS 6444-3 OR 6444-4
Fig. 58 Reverse Gear Thrust Washer
1 - REVERSE GEAR
2 - THRUST WASHER
Fig. 59 Reverse Gear, Bearing, And Stop Ring
1 - FIRST GEAR
2 - REVERSE GEAR ASSEMBLY
3 - BEARING ASSEMBLY
4 - STOP RING
Fig. 60 Reverse Gear Bearing Spacer And First Gear
Snap Ring
1 - CLUTCH GEAR SNAP RING
2 - REVERSE GEAR BEARING SPACER
BR/BEMANUAL - NV4500 21 - 19
MANUAL - NV4500 (Continued)

CLEANING
Clean the gears, shafts, shift components and trans-
mission housings with a standard parts cleaning sol-
vent. Do not use acid or corrosive base solvents. Dry
all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Replace the gear if the teeth are chipped, cracked or
worn thin.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Replace the retainer if worn or
damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap
ring grooves and threads. Replace the shaft if any
surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or
damage.
Inspect shift forks for 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 oversize or damaged. Do not attempt
to salvage a worn fork. Replace shift fork roll pins if
necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots,
pitting or other damage. Replace the bearings if nec-
essary.
Inspect the blocker rings and fiction cones. replace
either part if worn or damaged in any way. Replace if
the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
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.
Inspect the case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. Inspcet
the alignment dowels in the case top surface and in
the housing/adapter are tight and in good condition.
Replace the gear case or housing/adapter if cracked
or broken.
Fig. 61 Reverse Clutch Gear
1 - REVERSE CLUTCH GEAR
Fig. 62 First Gear
1 - FIRST GEAR
Fig. 63 First Gear Bearing
1 - MAINSHAFT
2 - FIRST GEAR BEARING
21 - 20 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(6)Install countershaft rear bearing plate (Fig. 72).
NOTE: Verify plate is seated in reverse idler shaft
notch and end play shims are still in position
before installing bolts.
(7) Apply 1-2 drops Mopar Loc N' Seal or equiva-
lent to threads of rear bearing plate bolts. Then
install and tighten bearing plate bolts to 23 N´m (200
in. lbs.).
SHIFT LUG AND RAIL
(1) Lubricate shift lug and rail with CastroltSyn-
torq or equivalent.
(2) Insert shift lug rail part way into case.
(3) Install shift lug on rail.
(4) Position shift rail so roll pin notches are
toward outside of case (Fig. 76).
(5) Install roll pin that secures lug to rail (Fig. 76).
MAINSHAFT AND GEARTRAIN
CAUTION: The reverse, 1-2 and 3-4 synchro compo-
nents can be assembled and installed incorrectly.
Follow assembly procedures for component identi-
fication and location.
Lubricate mainshaft bearing surfaces and all bear-
ing assemblies with CastroltSyntorq or with petro-
leum jelly.
(1) Install first snap ring in rear most groove of
mainshaft hub (Fig. 77). This snap ring locates first
gear clutch gear on shaft.NOTE: Four of these snap rings are used to secure
various components on the mainshaft 1-2 synchro
hub. The snap rings are all the same size and are
interchangeable.
(2) Install first gear clutch cone on mainshaft 1-2
synchro hub with recessed side of cone facing front
(Fig. 78). Verify cone is seated against snap ring on
hub.
(3) Install snap ring on mainshaft 1-2 synchro hub
to secure clutch cone (Fig. 79). Verify snap ring is
seated in hub groove and against clutch cone.
(4) Support mainshaft in upright position to install
remaining gears, snap rings and synchro compo-
nents. Shaft can be supported in gear case or hole
can be cut in workbench to support shaft.
Fig. 76 Shift Lug And Rail
1 - NOTCHES (FOR 5TH GEAR SHIFT FORK ROLL PINS)
2 - LUG RAIL
3 - ROLL PIN HOLE
4 - SHIFT LUG
Fig. 77 First Gear Bearing and Snap Ring
1 - SNAP RING
2 - FIRST GEAR BEARING
3 - MAINSHAFT SYNCHRO HUB
Fig. 78 First Gear Clutch Cone
1 - MAINSHAFT 1-2 SYNCHRO HUB
2 - FIRST GEAR CLUTCH CONE
21 - 24 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(5) If 1-2 synchro hub and sleeve were disassem-
bled for service, reassemble hub, sleeve, struts and
springs as follows:
(a) Align and install sleeve on hub. Rotate sleeve
until it slides onto hub. Sleeve only fits one way
and will easily slide onto hub when long slot in
sleeve, aligns with long shoulder on hub (Fig. 80).
(b) Place wood blocks under hub that will raise
hub about 3.5 cm (1.375 in.) above surface of work-
bench. Then allow sleeve to drop down on hub (Fig.
81).
(c) Install springs and struts in hub (Fig. 81).
Use lots of petroleum jelly to hold them in place.
Then compress struts with your fingers and move
sleeve upward until struts are started in sleeve.
Verify that struts are engaged in sleeve before pro-
ceeding.
(d) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated
and springs are not displaced during assembly.
(6) Install first gear stop ring in 1-2 synchro hub
and sleeve (Fig. 82). Verify stop ring is seated and
engaged in hub and sleeve.
Fig. 79 First Gear Clutch Cone Snap Ring
1 - FIRST GEAR CLUTCH CONE
2 - MAINSHAFT 1-2 SYNCHRO HUB
3 - CLUTCH CONE SNAP RING
Fig. 80 1-2 Synchro Sleeve On Hub
1 - ALIGN WIDE SLOT IN SLEEVE WITH WIDE SPLINE OF HUB
2 - 1-2 SLEEVE AND HUB
Fig. 81 1-2 Synchro Struts And Springs
1 - WOOD BLOCKS
2 - HUB
3 - SLEEVE
4 - STRUTS AND SPRINGS (4 EACH)
Fig. 82 First Gear Stop Ring In Synchro Hub
BR/BEMANUAL - NV4500 21 - 25
MANUAL - NV4500 (Continued)

(7) Install 1-2 synchro assembly and stop ring on
mainshaft with the taper on the sleeve facing for-
ward. (Fig. 83).
(8) Install snap ring that secures 1-2 synchro on
mainshaft hub (Fig. 84). Verify snap ring is seated in
groove in mainshaft hub.
(9) Assemble second gear clutch cone, clutch ring
and stop ring (Fig. 85).
(10) Install assembled second gear clutch cone and
rings on mainshaft and in 1-2 synchro hub (Fig. 86).
Fig. 83 1-2 Synchro
1 - MAINSHAFT HUB
2 - 1-2 SYNCHRO ASSEMBLY
3 - TAPERED SIDE OF SLEEVE
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
21 - 26 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

(11)Install snap ring that secures second gear clutch
cone on mainshaft (Fig. 87). Use narrow blade screw-
driver to work snap ring into hub groove as shown. Ver-
ify snap ring is seated in mainshaft groove.
NOTE: If snap ring will not fit in groove, clutch cone
is slightly misaligned.
(12) Install second gear bearing on mainshaft (Fig.
88).
(13) Install second gear on mainshaft and bearing.
Rotate gear until tabs of second gear clutch ring are
seated in tab slots in gear (Fig. 89).
(14) Install thrust washer pin in shaft (Fig. 90).
Fig. 87 Second Gear Clutch Cone Snap Ring
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
4 - SECOND GEAR CLUTCH CONE
Fig. 88 Second Gear Bearing
1 - SECOND GEAR BEARING
Fig. 89 Second Gear
1 - SECOND GEAR
2 - CLUTCH RING TABS
3 - TAB SLOTS (IN GEAR)
Fig. 90 Thrust Washer Pin
1 - THRUST WASHER PIN
2 - SECOND GEAR
BR/BEMANUAL - NV4500 21 - 27
MANUAL - NV4500 (Continued)

(a) Align and install synchro sleeve on hub (Fig.
96).Front side of hub has a narrow groove
machined in it.
(b) Insert all three synchro struts in slots
machined in sleeve and hub (Fig. 96).
(c) Install and seat synchro springs (Fig. 96).
Use screwdriver to compress springs and seat them
in struts and hub as shown.
(22) Start 3-4 synchro assembly on mainshaft with
the hub groove and sleeve groove both facing for-
ward. Tap assembly onto shaft splines until hub is
about 3 mm (0.125 in.) away from third gear stop
ring. Then align stop ring with synchro sleeve and
hub and seat synchro assembly with Installer C-4040
(Fig. 97).(23) Verify 3-4 synchro hub is seated on shaft with
approximately 3 mm (0.125 in.) of shaft spline visi-
ble.
NOTE: If hub is not seated, stop ring lugs are mis-
aligned. Rotate ring until lugs are engaged in 3-4
hub slots.
(24) Verify that second and third gear rotate freely
at this point. If not, determine the cause and correct.
(25) Invert mainshaft in case or bench.
(26) Install first gear bearing on mainshaft.
(27) Install first gear on shaft with clutch hub side
of gear facing the front of shaft (Fig. 98). Verify tabs
on clutch ring are aligned and seated in first gear
hub.
NOTE: 1-2 synchro hub will not seat properly if
clutch ring tabs are misaligned.
(28) Install reverse clutch gear on first gear (Fig.
98). Verify clutch gear is seated on shaft splines.
(29) Install reverse clutch gear snap ring with
heavy duty snap ring pliers (Fig. 98). Verify snap
ring is seated in groove.
NOTE: Reverse gear will not fit properly if snap ring
is not seated.
(30) Install stop ring on clutch cone (Fig. 99). Ver-
ify stop ring is seated on cone taper.
(31) Install reverse gear bearing spacer on main-
shaft and seat against reverse clutch gear snap ring
(Fig. 100).
(32) Install reverse gear bearing on mainshaft
(Fig. 100).
Fig. 96 Synchro Assembly (3-4)
1 - STRUT (3)
2 - SPRING (3)
3 - 3-4 SLEEVE
4 - 3-4 HUB
Fig. 97 Seating 3-4 Synchro Assembly On Mainshaft
1 - 3-4 SYNCHRO HUB
2 - HUB GROOVE
3 - INSTALLER C-4040
Fig. 98 First Gear And Clutch Gear
1 - FIRST GEAR
2 - REVERSE CLUTCH GEAR SNAP RING
3 - REVERSE CLUTCH GEAR
BR/BEMANUAL - NV4500 21 - 29
MANUAL - NV4500 (Continued)