2002 DODGE RAM Service Repair Manual

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Page 1457 of 2255

DODGE RAM 2002 Service Repair Manual 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 bi

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
generally 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
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift boot screws from floorpan and
slide boot upward on the shift lever.
(4) Remove shift lever extension from shift tower
and lever assembly.
(5) Remove shift tower bolts holding tower to iso-
lator plate and transmission shift cover.
(6) Remove shift tower and isolator plate from
transmission shift cover.
(7) Raise and support vehicle.
(8) Remove skid plate, if equipped.
(9) Mark propeller shaft and axle yokes for instal-
lation reference and remove shaft/shafts.
(10) Remove exhaust system Y-pipe.
(11) Disconnect speed sensor and backup light
switch connectors.
(12) Support engine with safety stand and a wood
block.
(13) If transmission is to be disassembled for,
remove drain bolt at bottom of PTO cover and drain
lubricant (Fig. 4).
TWO WHEEL DRIVE
(1) Remove nuts/bolts attaching transmission to
rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(5) Remove transmission harness wires from clips
on transmission shift cover.
(6) Remove transmission to clutch housing bolts.
(7) Slide transmission and jack rearward until
input shaft clears clutch housing.
(8) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever. Then remove transfer case shift
mechanism from transmission (Fig. 5).
(2) Support and secure transfer case to transmis-
sion jack with safety chains.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove transmission harness from retaining
clips on transmission shift cover.
(8) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(9) Remove rear crossmember.
(10) Remove clutch slave cylinder splash shield, if
equipped.
Fig. 4 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
21 - 4 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

Page 1458 of 2255

DODGE RAM 2002 Service Repair Manual (11) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever. This
reduces pressure on lever and release bearing mak-
ing transmission removal/installation easi

Page 1459 of 2255

DODGE RAM 2002 Service Repair Manual (4) Install splined Socket 6993 4X2 Socket 6984
4X4 to retain mainshaft while removing the fifth
gear nut.
(5) Install breaker bar in socket wrench (Fig. 9)
NOTE: Wedge breaker bar handle against work

Page 1460 of 2255

DODGE RAM 2002 Service Repair Manual (7) Remove countershaft fifth gear needle bearing
assembly (Fig. 12).
(8) Remove cone shaped rear bearing thrust
washer from end of countershaft (Fig. 13). Note posi-
tion of washer and washer bore no

Page 1461 of 2255

DODGE RAM 2002 Service Repair Manual (18) Remove mainshaft rear bearing plate bolts
and remove fifth gear plate end play shims and bear-
ing cup (Fig. 18).
FRONT RETAINER
(1) Remove and discard front bearing retainer
bolts (Fig. 19). Do

Page 1462 of 2255

DODGE RAM 2002 Service Repair Manual (7) Install assembled tools in front retainer (Fig.
22) with puller jaws seated under bearing cup.
(8) Place Insert Tool 6453-2 in center of puller
jaws, to hold puller jaws in place (Fig. 22).
(9) In

Page 1463 of 2255

DODGE RAM 2002 Service Repair Manual DRIVE GEAR
(1) Remove drive gear (Fig. 24).
(2) Remove pilot bearing from drive gear (Fig. 25).(3) Remove tapered bearing from drive gear with
Puller Flange 6444-1 and Puller Rods 6444-6 (Fig.
26). Th

Page 1464 of 2255

DODGE RAM 2002 Service Repair Manual MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 27).
(3) Remove fourth gear clutch gear and synchro

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