2003 DODGE RAM Service Repair Manual

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Page 1937 of 2895

DODGE RAM 2003 Service Repair Manual (10) Remove geartrain from the clutch housing and
install the geartrain into Support Stand 8246 (Fig.
30).
(11) Remove Fixture 8232 from the output shaft
and the countershaft.
(12) Separate the counte

Page 1938 of 2895

DODGE RAM 2003 Service Repair Manual OUTPUT SHAFT BEARINGS
(1) Remove snap-ring holding the pocket bearing
onto the output shaft.
(2) Remove pocket bearing from the output shaft
with Sleeve 6444-8, Jaws 8234, Puller Rods 6444-4
and the r

Page 1939 of 2895

DODGE RAM 2003 Service Repair Manual (3) Remove output shaft pocket bearing race from
the input shaft with Puller L-4518 (Fig. 36).
(4) Remove input shaft bearing and oil guide from
the input shaft with Collar 6444-8, Jaws 8243, Puller
R

Page 1940 of 2895

DODGE RAM 2003 Service Repair Manual (10) Remove sixth gear and the sixth gear bearing
from the output shaft (Fig. 41).
Fig. 39 FIRST GEAR BLOCKER RINGS AND
FRICTION CONE
1 - OUTPUT SHAFT
2 - FIRST GEAR BLOCKER RINGS
3 - FIRST GEAR FRICT

Page 1941 of 2895

DODGE RAM 2003 Service Repair Manual COUNTERSHAFT
(1) Install the countershaft into Fixture 8227 with
press blocks located under the fifth countershaft
gear.
(2) Place the assembly into a shop press.
(3) Use Guide 8235 on end of counters

Page 1942 of 2895

DODGE RAM 2003 Service Repair Manual (9) Place assembly into a shop press and press
third countershaft gear, 3-4 synchro and fourth coun-
tershaft gear bearing sleeve from the countershaft
(Fig. 45).
(10) Remove countershaft from the pre

Page 1943 of 2895

DODGE RAM 2003 Service Repair Manual (2) Remove countershaft oil guide from the coun-
tershaft front bearing bore in the clutch housing (Fig.
48).
(3) Remove countershaft front bearing race, end-
play shims and spacer from the clutch hou

Page 1944 of 2895

DODGE RAM 2003 Service Repair Manual Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or dam-
age.
Inspect shift forks for wear and distortion. Check
fit of the sleeve in the fork to be s

Inspect the countershaft and bearings. Replace the
shaft if any surfaces exhibit considerable wear or dam-
age.
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, pit-
ting or other damage. Replace the bearings if necessary.
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. Inspcet 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 used in the transmission.
Use Mopar Gasket Maker or equivalent on all gear
case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Place second gear on bench with the synchro
clutch ring up.
(2) Install second gear synchro inner blocker ring
onto second gear (Fig. 51).(3) Install second gear synchro friction cone over
the blocker ring and onto second gear (Fig. 52).
(4) Install second gear synchro outer blocker ring
over the second gear synchro friction cone. Align one
of the lugs on the outer ring with a lug on the inner
ring (Fig. 53).
Fig. 51 INNER BLOCKER RING
1 - INNER BLOCKER RING
2 - GEAR
Fig. 52 FRICTION CONE
1 - GEAR
2 - FRICTION CONE
Fig. 53 OUTER BLOCKER RING
1 - OUTER BLOCKER RING
2 - LUG
3 - GEAR
DRMANUAL TRANSMISSION - NV5600 21 - 105
MANUAL TRANSMISSION - NV5600 (Continued)

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