2002 DODGE RAM Service Repair Manual

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Page 1489 of 2255

DODGE RAM 2002 Service Repair Manual (7) Hold mainshaft Socket 6993 4X2 or Socket
6984 4X4 while installing the fifth gear nut.
(8) Tighten fifth gear nut as much as possible with
Nut Wrench 6743, long handle ratchet, breaker bar
and app

Page 1490 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
NOTE: If a new transmission is being installed, use
all components supplied with the new transmission.
For example, if a new shift tower is supplied with
the new transmission, do not re-u

INSTALLATION
NOTE: If a new transmission is being installed, use
all components supplied with the new transmission.
For example, if a new shift tower is supplied with
the new transmission, do not re-use the original
shift tower.
(1) Apply light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
the following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
(4) Raise transmission until input shaft is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start input
shaft in release bearing, clutch disc and pilot bush-
ing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-clutch hous-
ing bolts to 108 N´m (80 ft. lbs.).
(8) Install transmission mount on transmission or
rear crossmember.
(9) Install rear crossmember.
(10) Remove transmission jack and engine support
fixture.
(11) Position transmission harness wires in clips
on shift cover.
(12) Install clutch slave cylinder and install slave
cylinder shield, if equipped.
(13) Connect speed sensor and backup light switch
wires.
TWO WHEEL DRIVE
(1) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(2) Align and install propeller shaft.
(3) Lower vehicle.
(4) Clean the mating surfaces of shift tower, isola-
tor plate and shift cover with suitable wax and
grease remover.
(5) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.(6) Install the isolator plate onto the shift cover,
metal side down.
(7) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(8) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(9) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(10) Install the shift lever extension onto the shift
tower and lever assembly.
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install transfer case shift mechanism on trans-
mission.
(2) Install transfer case on transmission jack.
Secure transfer case to jack with safety chains.
(3) Raise jack and align transfer case input gear
with transmission mainshaft.
(4) Move transfer case forward and seat it on
adapter.
(5) Install and tighten transfer case attaching
nuts. Tighten nuts to 41-47 N´m (30-35 ft. lbs.) if
case has 3/8 studs or 30-41 N´m (22-30 ft. lbs.) if case
has 5/16 studs.
(6) Install transfer case shift mechanism to side of
transfer case.
(7) Connect transfer case shift lever to range lever
on transfer case.
(8) Align and connect propeller shafts.
(9) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(10) Install transfer case skid plate, if equipped
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(11) Install exhaust system components.
(12) Lower vehicle.
(13) Clean the mating surfaces of shift tower, iso-
lator plate and shift cover with suitable wax and
grease remover.
(14) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the shift cover. Do not over
apply sealant.
(15) Install the isolator plate onto the shift cover,
metal side down.
(16) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
the isolator plate.
(17) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
BR/BEMANUAL - NV4500 21 - 37
MANUAL - NV4500 (Continued)

Page 1491 of 2255

DODGE RAM 2002 Service Repair Manual (18) Install the bolts to hold the shift tower to the
isolator plate and the shift cover. Tighten the shift
tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(19) Install the shift lever extension

Page 1492 of 2255

DODGE RAM 2002 Service Repair Manual Installer Bushing 8156
Handle C-4171
Installer Seal C-3972-A
Installer Seal 8154
Installer Seal C-3860-A
Wrench 6443
Wrench 6743
Socket 6441
Socket 6442
Socket 6993
BR/BEMANUAL - NV4500 21 - 39
MANUAL

Page 1493 of 2255

DODGE RAM 2002 Service Repair Manual Socket 6984
Puller 6444
Jaws 6459
Jaws 6820
Jaws and Insert 6453
Jaws 6447
Jaws 6449
Jaws 6451
Remover 6454
21 - 40 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)

Page 1494 of 2255

DODGE RAM 2002 Service Repair Manual Installer 6061
Installer C-4340
Installer C-4040
Installer 6448
Installer C-4308
Installer 6052
Rod Extension 8161
Installer 6446
Jaws 6445
BR/BEMANUAL - NV4500 21 - 41
MANUAL - NV4500 (Continued)

Page 1495 of 2255

DODGE RAM 2002 Service Repair Manual ADAPTER HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support vehicle.
(2) Mark the propeller shafts and yokes for instal-
lation reference and remove the shafts.
(3) Support transmission with a transmi

Page 1496 of 2255

DODGE RAM 2002 Service Repair Manual (4) Check and fill transmission.
(5) Remove support and lower vehicle.
SHIFT MECHANISM - NV4500
REMOVAL
(1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 132).
(3) Pry up shift

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