2002 DODGE RAM Service Repair Manual

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Page 1465 of 2255

DODGE RAM 2002 Service Repair Manual (2) Remove countershaft end play shim and rear
bearing cup (Fig. 31).
(3) Remove reverse idler shaft (Fig. 32).
(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and t

Page 1466 of 2255

DODGE RAM 2002 Service Repair Manual (7) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them
together for cleaning and inspection.
(8) To remove countershaft rear bearing ,assemble
Puller Flange 6

(7) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them
together for cleaning and inspection.
(8) To remove countershaft rear bearing ,assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
36).
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.
(9) Position first Puller Jaw 6449 on bearing cone
(10) Seat puller flange in notch of puller jaw just
installed on bearing cone
(11) Install second Puller Jaw 6449 on bearing and
in notch of puller flange
(12) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(13) Install Puller 6444 on puller rods, then secure
puller to rods with retaining nuts
(14) Tighten puller bolt to remove bearing from
shaft. If bearing is exceptionally tight, tap end of
puller bolt with copper mallet to help loosen bearing.
(15) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 37).
(16) ToRemove countershaft front bearing, assem-
ble Puller Flange 6444-1 and Puller Bolts 6444-4
(Fig. 38).
(17) Position first Puller Jaw 6451 on bearing.
(18) Seat puller flange in notch of puller jaw.
(19) Install second Puller Jaw 6451 on bearing and
in notch of puller flange.(20) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(21) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts
(22) Tighten puller bolt to remove bearing from
shaft. If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(23) Remove bearing puller tools.
Fig. 36 Countershaft Rear Bearing
1 - COLLAR 6444-8
2 - JAWS 6449
3 - PULLER 6444
4 - WRENCH
Fig. 37 Countershaft And Case
1 - COUNTERSHAFT
Fig. 38 Countershaft Front Bearing
1 - JAWS 6451
2 - COLLAR 6444-8
3 - PULLER 6444
4 - FLANGE 6444-1
BR/BEMANUAL - NV4500 21 - 13
MANUAL - NV4500 (Continued)

Page 1467 of 2255

DODGE RAM 2002 Service Repair Manual GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 39).
(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 40).
(3) Remove roll pin that secures shi

Page 1468 of 2255

DODGE RAM 2002 Service Repair Manual (6) Remove second gear thrust washer (Fig. 45).
Note washer notch for locating pin.
(7) Remove thrust washer locating pin (Fig. 46)
with needle nose pliers.
(8) Remove second gear (Fig. 47).
(9) Remov

Page 1469 of 2255

DODGE RAM 2002 Service Repair Manual (10) Remove second gear clutch cone snap ring
from mainshaft synchro hub groove (Fig. 49).
(11) Remove second gear clutch cone, synchro
clutch ring and synchro stop ring (Fig. 50).
(12) Remove 1-2 syn

Page 1470 of 2255

DODGE RAM 2002 Service Repair Manual (15) Remove first gear clutch cone front snap ring
from mainshaft hub (Fig. 54).
(16) Remove first gear clutch cone (Fig. 55).
(17) Remove first gear clutch gear rear snap ring
from mainshaft hub (Fig

Page 1471 of 2255

DODGE RAM 2002 Service Repair Manual (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 beari

Page 1472 of 2255

DODGE RAM 2002 Service Repair Manual (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

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