2003 DODGE RAM Service Repair Manual

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Page 1905 of 2895

DODGE RAM 2003 Service Repair Manual (6) Install first gear stop ring in 1-2 synchro hub
and sleeve (Fig. 84). Verify stop ring is seated and
engaged in hub and sleeve.
(7) Install 1-2 synchro assembly and stop ring on
mainshaft with the

Page 1906 of 2895

DODGE RAM 2003 Service Repair Manual (10) Install assembled second gear clutch cone and
rings on mainshaft and in 1-2 synchro hub (Fig. 88).
(11) Install snap ring that secures second gear
clutch cone on mainshaft (Fig. 89). Use narrow b

Page 1907 of 2895

DODGE RAM 2003 Service Repair Manual (14) Install thrust washer pin in shaft (Fig. 92).
(15) Install second gear thrust washer. Verify
washer is seated on gear and pin (Fig. 93).
(16) Install second gear thrust washer snap ring
(Fig. 94)

Page 1908 of 2895

DODGE RAM 2003 Service Repair Manual (20) Install synchro stop ring on third gear (Fig.
97). Verify stop ring is seated on cone taper.
(21) If 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align

Page 1909 of 2895

DODGE RAM 2003 Service Repair Manual (28) Install reverse clutch gear on first gear (Fig.
100). Verify clutch gear is seated on shaft splines.
(29) Install reverse clutch gear snap ring with
heavy duty snap ring pliers (Fig. 100). Verify

Page 1910 of 2895

DODGE RAM 2003 Service Repair Manual (e) Install second and third struts in same man-
ner as described in step (d).
(f) Work sleeve upward on hub until struts are
centered and seated in sleeve. Sleeve should be in
neutral position after

Page 1911 of 2895

DODGE RAM 2003 Service Repair Manual (42) Set transmission case upright (Fig. 109).
(43) Install drive gear thrust bearing on mainshaft
(Fig. 110). Use plenty of petroleum jelly to hold bear-
ing in place.
(44) Check alignment and mesh o

Page 1912 of 2895

DODGE RAM 2003 Service Repair Manual (5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 113). Use one or two wood
blocks to support retainer as shown. Lubricate seal
lip with petroleum jelly after installation.

(5) Install new oil seal in front bearing retainer
with Installer 6052 (Fig. 113). Use one or two wood
blocks to support retainer as shown. Lubricate seal
lip with petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover.
(7) Apply Mopar Silicone Sealer or equivalent to
flange surface of front bearing retainer (Fig. 114).
(8) Install front bearing retainer over drive gear
and start it into case.
(9) Start front bearing retainer in gear case. Verify
retainer lube channel is at the top-center(12
O'clock)position (Fig. 114).(10) Align front bearing retainer bolt holes and tap
retainer into place with plastic mallet. Installnew
retainer bolts and tighten to 30 N´m (22 ft. lbs.) (Fig.
115).
NOTE: Never reuse the old bolts.
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 position (Fig. 116).
NOTE: Do not install any end play shims at this
time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case in upright position on bench.
Either cut hole in bench to accept drive gear and
front retainer or use C-clamps to secure transmission
on bench.
NOTE: Do not leave transmission unsupported.
(5) Install Extension Rod 8161 into a suitable
threaded hole in rear of case.
(6) Mount dial indicator on extension rod and posi-
tion indicator plunger against end of mainshaft.
(7) Move mainshaft forward to remove all play
then zero dial indicator.
(8) Move mainshaft upward and record dial indica-
tor reading. Move mainshaft with pry tool positioned
between drive gear and case.
(9) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play.
If end play adjustment is required, remove bearing
plate and install necessary shim.
(10) Reinstall rear bearing plate with oil hole in
bearing plate at the top (Fig. 116).
(11) Apply Mopar Lock N' Seal or equivalent to
bearing plate bolt threads. Install and tighten bolts
to 23 N´m (200 in. lbs.).
Fig. 113 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - RETAINER
3 - WOOD BLOCK
Fig. 114 LOCATION OF FRONT RETAINER LUBE
CHANNEL
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 115 FRONT BEARING RETAINER
1 - DRIVE GEAR
2 - FRONT BEARING RETAINER
DRMANUAL TRANSMISSION - NV4500 21 - 73
MANUAL TRANSMISSION - NV4500 (Continued)

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