2003 DODGE RAM Service Repair Manual

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Page 1857 of 2895

DODGE RAM 2003 Service Repair Manual (2) Install reverse gear over needle bearing (Fig.
51).
(3) Install brass synchro ring on reverse gear (Fig.
52).
(4) Start fifth-reverse synchro assembly on output
shaft splines by hand. Then seat sy

Page 1858 of 2895

DODGE RAM 2003 Service Repair Manual (6) Install fifth gear synchro ring in synchro hub
and sleeve (Fig. 55).
(7) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 56).
Verify bearing is prope

Page 1859 of 2895

DODGE RAM 2003 Service Repair Manual (11) Install first gear on shaft and over bearing
(Fig. 59) with bearing synchro cone facing up.
(12) Install first gear synchro ring (Fig. 60).
(13) Start 1-2 synchro assembly on shaft by hand
(Fig.

Page 1860 of 2895

DODGE RAM 2003 Service Repair Manual (15) Install interm ring.
(16) Installnew1-2 synchro hub snap ring (Fig.
63). Verify snap ring is seated in shaft groove.
(17) Install second gear synchro ring in 1-2 syn-
chro hub and sleeve (Fig. 64

Page 1861 of 2895

DODGE RAM 2003 Service Repair Manual (21) Install two-piece thrust washer with halves
seated in the shaft groove and washer lugs seated in
shaft lug bores (Fig. 67). Verify i.d. grooves and
markings noted during removal are facing the co

Page 1862 of 2895

DODGE RAM 2003 Service Repair Manual (24) Install third gear needle bearing on shaft (Fig.
70).
(25) Install third gear on shaft and bearing (Fig.
71).(26) Install third speed synchro ring on third gear
(Fig. 72).
(27) Start 3-4 synchro

Page 1863 of 2895

DODGE RAM 2003 Service Repair Manual (28) Press 3-4 synchro assembly onto output shaft
with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to
output shaft as possible but not contacting the
shaft

Page 1864 of 2895

DODGE RAM 2003 Service Repair Manual Fig. 77 SYNCHRO SLEEVE LOCATIONS
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCH

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