2002 DODGE RAM Service Repair Manual

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Page 1529 of 2255

DODGE RAM 2002 Service Repair Manual (3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4

Page 1530 of 2255

DODGE RAM 2002 Service Repair Manual (10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 95).(11) Subtract thickness of the gau

Page 1531 of 2255

DODGE RAM 2002 Service Repair Manual (24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com-
ponents supplied with the transmission. I

(24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com-
ponents supplied with the transmission. If a new
shift tower is supplied with the new transmission,
do not re-use the original shift tower.
(1) Apply a light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
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 clutch disc hub.
(5) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(6) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-engine
block bolts.
(8) Install clutch slave cylinder.
(9) Connect backup light switch wires.
(10) Position transmission harness wires in clips
on transmission.(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Fill transmission with required lubricant (Fig.
98). Check lubricant level in transfer case if
equipped.
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify shift tower, isolator plate and the shift
socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso-
lator plate and the transmission case. Tighten bolts
to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
Fig. 97 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
Fig. 98 FILL PLUG
1 - FILL PLUG
21 - 78 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

Page 1532 of 2255

DODGE RAM 2002 Service Repair Manual (3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts
to 41-47 N´m (30-35 ft. lbs.) if case has 3/8 studs. If
case has 5/16 studs tighten to 30-41

Page 1533 of 2255

DODGE RAM 2002 Service Repair Manual SPECIAL TOOLS
REMOVER 8155
INSTALLER 8156
HANDLE C-4171
INSTALLER C-3972-A
INSTALLER 8154
WRENCH 8226
SOCKET 6984
21 - 80 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

Page 1534 of 2255

DODGE RAM 2002 Service Repair Manual PULLER 6444
PULLER JAWS 6447
PULLER JAWS 6451
INSTALLER 6061
INSTALLER 6448
INSTALLER C-4308
EXTENSION ROD 8161
FIXTURE 8227
BR/BEMANUAL - NV5600 21 - 81
MANUAL - NV5600 (Continued)

Page 1535 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLER 8228
FIXTURE 8230
ADAPTER 8232
REMOVER 8233
REMOVER 8234
GUIDE 8235
INSTALLER 8236
INSTALLER/REMOVER 8237
21 - 82 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

Page 1536 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLER/REMOVER 8238
INSTALLER 8239
REMOVER 8240
FIXTURE 8241
HOLDING TOOL 8242
REMOVER 8243
PULLER 8244
REMOVER 8245
BR/BEMANUAL - NV5600 21 - 83
MANUAL - NV5600 (Continued)

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