2002 DODGE RAM Service Repair Manual

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Page 1481 of 2255

DODGE RAM 2002 Service Repair Manual (15) Install second gear thrust washer. Verify
washer is seated on gear and pin (Fig. 91).
(16) Install second gear thrust washer snap ring
(Fig. 92). Verify snap ring is seated in mainshaft
groove.
(

Page 1482 of 2255

DODGE RAM 2002 Service Repair Manual (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) Insta

(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)

Page 1483 of 2255

DODGE RAM 2002 Service Repair Manual (33) If reverse gear sleeve and struts were disas-
sembled for service, reassemble sleeve, struts and
springs as follows:
CAUTION: The reverse sleeve will fit either way on
the hub. Verify tapered sid

Page 1484 of 2255

DODGE RAM 2002 Service Repair Manual (37) Install fourth gear stop ring in 3-4 synchro
sleeve (Fig. 105).(38) Install fourth gear clutch gear in stop ring
(Fig. 106).
(39) Roll gear case onto its left side.
(40) Grip mainshaft at pilot b

Page 1485 of 2255

DODGE RAM 2002 Service Repair Manual DRIVE GEAR AND RETAINER
(1) Install bearing on drive gear with Installer
6448 (Fig. 109).
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on

Page 1486 of 2255

DODGE RAM 2002 Service Repair Manual MAINSHAFT END PLAY
(1) Install mainshaft rear bearing cup in case and
over bearing. Tap bearing cup into place with plastic
mallet.
(2) Install rear bearing plate to hold mainshaft
and rear bearing in

MAINSHAFT END PLAY
(1) Install mainshaft rear bearing cup in case and
over bearing. Tap bearing cup into place with plastic
mallet.
(2) Install rear bearing plate to hold mainshaft
and rear bearing in position (Fig. 114).
NOTE: Do not install any end play shims at this
time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case in upright position on bench.
Either cut hole in bench to accept drive gear and
front retainer or use C-clamps to secure transmission
on bench.
NOTE: Do not leave transmission unsupported.
(5) Install Extension Rod 8161 into a suitable
threaded hole in rear of case.(6) Mount dial indicator on extension rod and posi-
tion indicator plunger against end of mainshaft.
(7) Move mainshaft forward to remove all play
then zero dial indicator.
(8) Move mainshaft upward and record dial indica-
tor reading. Move mainshaft with pry tool positioned
between drive gear and case.
(9) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play.
If end play adjustment is required, remove bearing
plate and install necessary shim.
(10) Reinstall rear bearing plate with oil hole in
bearing plate at the top (Fig. 114).
(11) Apply Mopar Lock N' Seal or equivalent to
bearing plate bolt threads. Install and tighten bolts
to 23 N´m (200 in. lbs.).
(12) Install mainshaft fifth gear with Installer
6446 (Fig. 115). Gear is seated when it contacts rear
bearing.
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) Install thrust washer pin in countershaft (Fig.
116).
(2) Install thrust washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 117).
NOTE: The flat side of washer faces the rear and
cone side faces the front.
(3) Lubricate and install fifth gear bearing on
countershaft (Fig. 118).
(4) Install synchro sleeve on hub of countershaft
fifth gear with tapered side of sleeve facing front and
the flat side facing rear (Fig. 119).
(5) Install shift fork in synchro sleeve (Fig. 120).
Fig. 112 Location Of Front Retainer Lube Channel
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 113 Front Bearing Retainer
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
Fig. 114 Rear Bearing Plate
1 - BEARING PLATE OIL HOLE (AT TOP)
2 - MAINSHAFT REAR BEARING PLATE
BR/BEMANUAL - NV4500 21 - 33
MANUAL - NV4500 (Continued)

Page 1487 of 2255

DODGE RAM 2002 Service Repair Manual Fig. 115 Mainshaft Fifth Gear
1 - MAINSHAFT FIFTH GEAR
2 - INSTALLER 6446
Fig. 116 Fifth Gear Thrust Washer Pin
1 - THRUST WASHER PIN
2 - COUNTERSHAFT
Fig. 117 Fifth Gear Thrust Washer
1 - PIN
2 - THR

Page 1488 of 2255

DODGE RAM 2002 Service Repair Manual (6) Install assembled fifth gear, synchro sleeve and
shift fork (Fig. 121). Align fork with shift lug rail and
align gear with bearings and countershaft. Start
components onto shaft and rail, then tap

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