2003 DODGE RAM Service Repair Manual

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Page 1953 of 2895

DODGE RAM 2003 Service Repair Manual NOTE: Do not replace the input shaft seal at this
time. A new seal will be installed after all the pre-
load measurements are made and endplay shims
are installed.
(5) Install input shaft retainer ont

Page 1954 of 2895

DODGE RAM 2003 Service Repair Manual (6) Install Fixture 8232 to the output shaft and
countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5-6 synchro
together during the remainder of the ins

Page 1955 of 2895

DODGE RAM 2003 Service Repair Manual (13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts and
tighten to 28 N´m (20 ft. lbs.) (Fig. 82).
(15) Remove engine crane and Fixture

Page 1956 of 2895

DODGE RAM 2003 Service Repair Manual (3) Measure countershaft end-play with Dial Indi-
cator Set C-3339 and Extension Rod 8161 installed
onto the rear of the transmission gear case (Fig. 85).
(4) Rotate transmission into a horizontal pos

Page 1957 of 2895

DODGE RAM 2003 Service Repair Manual (4) Install reverse gear, reverse gear synchronizer
cone, reverse gear outer blocker ring and reverse
gear bearing (Fig. 88).
(5) Install output shaft ball bearing assembly and
reverse thrust washer o

Page 1958 of 2895

DODGE RAM 2003 Service Repair Manual (13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 81

(13) Install reverse idler thrust washer from the
reverse idler.
(14) Install crossover cam rollers and pin (Fig. 91).
EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171, if necessary. The
oil feed hole must be at the 12 o'clock position when
installed.
(2) On 4X2 vehicles, install extension housing seal
with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(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-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 92).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(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. 93).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.(12)
The difference between the two measurements is
the end-play for the reverse countershaft gear assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.006-
0.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
Fig. 91 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 92 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
Fig. 93 MEASURE DEPTH OF REVERSE
COUNTERSHAFT GEAR BEARING RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
DRMANUAL TRANSMISSION - NV5600 21 - 119
MANUAL TRANSMISSION - NV5600 (Continued)

Page 1959 of 2895

DODGE RAM 2003 Service Repair Manual (14) Use Installer to install the reverse counter-
shaft bearing race into the extension/adapter hous-
ing.
(15) Install back-up lamp switch into the exten-
sion/adapter housing and tighten to 28 N´m

(14) Use Installer to install the reverse counter-
shaft bearing race into the extension/adapter hous-
ing.
(15) Install back-up lamp switch into the exten-
sion/adapter housing and tighten to 28 N´m (20
ft.lbs.).
(16) Install crossover cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 94).
(18) Install crossover detent plunger, spring and
plug into the extension/adapter housing. Tighten the
plug to 47.5 N´m (35 ft.lbs.) (Fig. 95).
(19) Apply sealer to the surface of the transmis-
sion case.(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter
housing onto the transmission gear case. Tighten
bolts to 48 N´m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N´m (41 ft.lbs.).
(23) Install primary shift rail detent plunger,
spring and plug into the transmission case. Tighten
detent plug to 47.5 N´m (35 ft.lbs.).
(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.
96). Check lubricant level in transfer case if
equipped.
Fig. 94 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
Fig. 95 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
21 - 120 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

Page 1960 of 2895

DODGE RAM 2003 Service Repair Manual 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

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.
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.
(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 N´m (22-30 ft.
lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.
(6) Install propeller shafts with reference marks
aligned.
(7) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(8) Install exhaust system components.
(9) Remove support and lower vehicle.
(10) Shift transmission into third gear.
(11) Clean the mating surfaces of shift tower, iso-
lator plate and transmission case with suitable wax
and grease remover.
(12) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission case. Do not
over apply sealant.
(13) Install isolator plate onto the transmission
case, metal side down.
(14) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(15) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(16) Install the bolts to hold the shift tower to the
isolator plate and the transmission case. Tighten the
shift tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(17) Install shift lever boot and bezel.
Fig. 96 FILL PLUG
1 - FILL PLUG
DRMANUAL TRANSMISSION - NV5600 21 - 121
MANUAL TRANSMISSION - NV5600 (Continued)

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