2003 DODGE RAM Service Repair Manual

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Page 1897 of 2895

DODGE RAM 2003 Service Repair Manual (16) Remove first gear clutch cone (Fig. 57).
(17) Remove first gear clutch gear rear snap ring
from mainshaft hub (Fig. 57).
NOTE: Do not remove this snap ring unless main-
shaft is being replaced.
(

Page 1898 of 2895

DODGE RAM 2003 Service Repair Manual (21) Install Puller 6444 on the puller rods and
secure with nuts (Fig. 59). Tighten puller bolt to the
remove bearing.
(22) Remove bearing puller tools and rear main-
shaft bearing from output shaft.

Page 1899 of 2895

DODGE RAM 2003 Service Repair Manual (28) Remove reverse clutch gear (Fig. 63).
(29) Remove first gear from bearing and mainshaft
(Fig. 64).
(30) Remove first gear bearing from mainshaft
(Fig. 65).
CLEANING
Clean the gears, shafts, shift

(28) Remove reverse clutch gear (Fig. 63).
(29) Remove first gear from bearing and mainshaft
(Fig. 64).
(30) Remove first gear bearing from mainshaft
(Fig. 65).
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Inspect the reverse idler gear, bearings, shaft and
thrust washers. Replace the bearings if the rollers
are worn, chipped, cracked, flat-spotted or brinnelled.
Replace the gear if the teeth are chipped, cracked or
worn thin.
Inspect the front bearing retainer and bearing cup.
Replace the bearing cup if scored, cracked, brinnelled
or rough. Check the release bearing slide surface of
the retainer carefully. Replace the retainer if worn or
damaged in any way.
Inspect mainshaft bearing surfaces, splines, snap
ring grooves and threads. Replace the shaft if any
surfaces exhibit considerable wear or damage.
Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or
damage.
Inspect shift forks for wear and distortion. Check
fit of the sleeve in the fork to be sure the two parts
fit and work smoothly. Replace the fork if the roll pin
holes are worn oversize or damaged. Do not attempt
to salvage a worn fork. Replace shift fork roll pins if
necessary or if doubt exists about their condition.
The all bearings for wear, roughness, flat spots,
pitting or other damage. Replace the bearings if nec-
essary.
Inspect the blocker rings and fiction cones. replace
either part if worn or damaged in any way. Replace if
the friction material is burned, flaking off or worn.
Inspect synchro components wear or damage.
Replace parts if worn, cracked or distorted.
Inspect all of the thrust washers and locating pins.
Replace the pins if bent or worn. Replace the wash-
ers if worn or the locating pin notches are distorted.
Inspect the case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. InspcetFig. 63 Reverse Clutch Gear
1 - REVERSE CLUTCH GEAR
Fig. 64 FIRST GEAR
1 - FIRST GEAR
Fig. 65 FIRST GEAR BEARING
1 - MAINSHAFT
2 - FIRST GEAR BEARING
21 - 60 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

Page 1900 of 2895

DODGE RAM 2003 Service Repair Manual the alignment dowels in the case top surface and in
the housing/adapter are tight and in good condition.
Replace the gear case or housing/adapter if cracked
or broken.
ASSEMBLY
NOTE: Gaskets are not u

Page 1901 of 2895

DODGE RAM 2003 Service Repair Manual (8) Install reverse idler gear in case (Fig. 69).
(9) Install idler gear rear thrust washer between
idler gear and case boss (Fig. 69).
(10) Align idler gear bearings and thrust washers
with a drift.

Page 1902 of 2895

DODGE RAM 2003 Service Repair Manual (18) Apply Mopar silicone adhesive/sealer or equiv-
alent to flange and lip of new cap. Installnewfront
bearing cap in gear case (Fig. 75) with Handle
C-4171 and Installer C-3972-A.
COUNTERSHAFT END P

Page 1903 of 2895

DODGE RAM 2003 Service Repair Manual (6) Install countershaft rear bearing plate (Fig.
74).
NOTE: Verify plate is seated in reverse idler shaft
notch and end play shims are still in position
before installing bolts.
(7) Apply 1-2 drops M

Page 1904 of 2895

DODGE RAM 2003 Service Repair Manual (3) Install snap ring on mainshaft 1-2 synchro hub
to secure clutch cone (Fig. 81). Verify snap ring is
seated in hub groove and against clutch cone.
(4) Support mainshaft in upright position to insta

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