2002 DODGE RAM Service Repair Manual

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

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

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