2002 DODGE RAM Service Repair Manual

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Page 1449 of 2255

DODGE RAM 2002 Service Repair Manual LINKAGE - 2WD
TABLE OF CONTENTS
page page
LINKAGE - 2WD
DESCRIPTION.........................40
STANDARD PROCEDURE - LUBRICATION....40
REMOVAL.............................40
INSTALLATION...............

Page 1450 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
(1) Position idler arm on the frame bracket and
tighten the bolt to specification.
(2) Center steering gear to alignment marks and
install pitman arm.
(3)
Install the lock washer and reta

Page 1451 of 2255

DODGE RAM 2002 Service Repair Manual LINKAGE - 4WD
TABLE OF CONTENTS
page page
LINKAGE - 4WD
DESCRIPTION.........................42
STANDARD PROCEDURE - LUBRICATION....42
REMOVAL.............................42
INSTALLATION...............

Page 1452 of 2255

DODGE RAM 2002 Service Repair Manual (6) Mark the pitman arm and shaft positions for
installation reference. Remove the nut and washer
from the pitman arm. Remove the pitman arm with
Puller C-4150A.
INSTALLATION
(1) Align reference marks

Page 1453 of 2255

DODGE RAM 2002 Service Repair Manual SPECIAL TOOLS
STEERING LINKAGE
Remover Ball Stud MB-991113
Puller Tie Rod C-3894-A
Remover Pitman C-4150A
19 - 44 LINKAGE - 4WDBR/BE
LINKAGE - 4WD (Continued)

Page 1454 of 2255

DODGE RAM 2002 Service Repair Manual TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV4500........................1
MANUAL - NV5600.......................46
AUTOMATIC TRANSMISSION - 46RE.........87AUTOMATIC TRANSMISS

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV4500........................1
MANUAL - NV5600.......................46
AUTOMATIC TRANSMISSION - 46RE.........87AUTOMATIC TRANSMISSION - 47RE........259
TRANSFER CASE - NV241LD..............430
TRANSFER CASE - NV241HD.............465
MANUAL - NV4500
TABLE OF CONTENTS
page page
MANUAL - NV4500
DESCRIPTION..........................1
OPERATION............................3
DIAGNOSIS AND TESTING................3
REMOVAL.............................4
DISASSEMBLY..........................5
CLEANING............................20
INSPECTION..........................20
ASSEMBLY............................21
INSTALLATION.........................37
SPECIFICATIONS.......................38
SPECIAL TOOLS.......................38ADAPTER HOUSING SEAL - NV4500
REMOVAL.............................42
INSTALLATION.........................42
EXTENSION HOUSING SEAL - NV4500
REMOVAL.............................42
INSTALLATION.........................42
SHIFT MECHANISM - NV4500
REMOVAL.............................43
INSTALLATION.........................44
SHIFT COVER - NV4500
REMOVAL.............................45
INSTALLATION.........................45
MANUAL - NV4500
DESCRIPTION
The NV4500 is a five speed constant mesh manual
transmission (Fig. 1). All gear ranges including
reverse are synchronized. Fifth gear is an overdrive
range. The transmission has a cast iron gear case
and aluminum shift cover.
Two versions are used, a standard duty for 5.9L
applications and a heavy duty for V10 and Cummins
diesel applications. Main differences are the larger
diameter input shaft, output shaft and mainshaft
fifth gear in the heavy duty model.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Roller
bearings in the drive gear support the forward end ofthe mainshaft. The mainshaft gears are all supported
on caged type roller bearings. Drive gear thrust reac-
tion is controlled by a needle type thrust bearing.
The bearing is located at the forward end of the
mainshaft.
The transmission is a top loader style. The shift
lever is located in a shifter tower which is bolted to
the shift cover and operates the shift forks and rails
directly. The shift forks and rails are all located
within the aluminum cover which is bolted to the top
of the gear case.
SHIFT PATTERN
The shift pattern is in a modified H pattern (Fig.
2). Overdrive fifth and reverse gears are in line and
outboard of the first through fourth gear positions.
BR/BETRANSMISSION AND TRANSFER CASE 21 - 1

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DODGE RAM 2002 Service Repair Manual Fig. 1 NV4500 Manual Transmissions
Fig. 2 NV4500
21 - 2 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

Page 1456 of 2255

DODGE RAM 2002 Service Repair Manual GEAR RATIOS
GEAR RATIO
FIRST 5.61:1
SECOND 3.04:1
THIRD 1.67:1
FOURTH 1.00:1
FIFTH 0.75:1
REVERSE 5.04:1
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fi

GEAR RATIOS
GEAR RATIO
FIRST 5.61:1
SECOND 3.04:1
THIRD 1.67:1
FOURTH 1.00:1
FIFTH 0.75:1
REVERSE 5.04:1
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 3).
The tag provides the transmission model number,
build date and part number. Be sure to reinstall the
I.D. tag if removed during service. The information
on the tag is essential to correct parts ordering.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point all the transmission gears
are spinning.The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shift lever
moves the selected shift rail, the shift fork attached
to that rail begins to move. The fork is positioned in
a groove in the outer circumference of the synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer does
this by having the synchronizer hub splined to the
mainshaft, or the countershaft in some cases, and
moving the blocker ring into contact with the gear's
friction cone. As the blocker ring and friction cone
come together, the gear speed is brought up or down
to the speed of the synchronizer. As the two speeds
match, the splines on the inside of the synchronizer
sleeve become aligned with the teeth on the blocker
ring and the friction cone and eventually will slide
over the teeth, locking the gear to the mainshaft, or
countershaft, through the synchronizer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or an incor-
rect lubricant level check. 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 recommendations 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.
Leaks can occur at the mating surfaces of the gear
case, adaptor or extension housing, or from the front/
rear seals. A suspected leak could also be the result
of an overfill condition. Leaks at the rear of the
extension or adapter housing will be from the hous-
ing oil seals. Leaks at component mating surfaces
will probably be the result of inadequate sealer, gaps
in the sealer, incorrect bolt tightening or use of a
non-recommended sealer. A leak at the front of the
transmission will be from either the front bearing
retainer or retainer seal. Lubricant may be seen drip-
ping from the clutch housing after extended opera-
tion. If the leak is severe, it may also contaminate
the clutch disc causing the disc to slip, grab and or
chatter.
Fig. 3 Identification Tag Location
1 - PTO COVER
2 - I.D. TAG
BR/BEMANUAL - NV4500 21 - 3
MANUAL - NV4500 (Continued)

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