2003 DODGE RAM ECU

(11) Assemble Puller Flange 6444-1and Puller
Rods 6444-3 4X2 or 6444-4 4X4 (Fig. 17). Slide
assembly onto output shaft and seat flange in notch
of jaw.
(12) Position second puller jaw on gear and in
notch of puller flange (Fig. 18). Slide Collar 6444-8
over puller jaws to hold them in place.(13)Install Puller and Bolt 6444 on puller rods and
secure puller to rods with retaining nuts (Fig. 19).
Tighten puller bolt to remove gear from shaft splines.
(14) Remove mainshaft rear bearing plate bolts
and remove fifth gear plate end play shims and bear-
ing cup (Fig. 20).
Fig. 17 PULLER FLANGE
1-JAW
2 - PULLER FLANGE
Fig. 18 PULLER COLLAR
1-JAWS
2 - COLLAR
Fig. 19 PULLER ASSEMBLY
1 - COLLAR
2-JAWS
3 - BOLT
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE
Fig. 20 FIFTH GEAR BEARING PLATE, SHIMS AND
BEARING CUP
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
21 - 48 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(8) Remove countershaft rear bearing with Puller
Flange 6444-1 and Puller Rods 6444-4 (Fig. 38).
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.
(9) Position first Jaw 6449 on bearing cone and
seat puller flange in notch of puller.
(10) Install second Jaw 6449 on bearing and in
notch of puller flange. Slide Collar 6444-8 over puller
jaws to hold them in place.
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(11) Install Puller 6444 on puller rods, then secure
puller to rods with retaining nuts.Tighten puller bolt
to remove bearing from shaft.
NOTE: If bearing is exceptionally tight, tap end of
puller bolt with copper mallet to help loosen bear-
ing.
(12) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 39).
(13) Remove countershaft front bearing, with
Puller Flange 6444-1 and Puller Bolts 6444-4 (Fig.
40).
(14) Position first Jaw 6451 on bearing and seat
puller flange in notch of puller jaw.
(15) Install second Jaw 6451 on bearing and in
notch of puller flange. Slide Collar 6444-8 over puller
jaws to hold them in place.NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(16) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts. Tighten
puller bolt to remove bearing from shaft.
NOTE: If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(17) Remove bearing puller tools.
Fig. 38 COUNTERSHAFT REAR BEARING
1 - COLLAR
2-JAWS
3 - PULLER
4 - WRENCH
Fig. 39 COUNTERSHAFT AND CASE
1 - COUNTERSHAFT
Fig. 40 Countershaft Front Bearing
1-JAWS
2 - COLLAR
3 - PULLER
4 - FLANGE
DRMANUAL TRANSMISSION - NV4500 21 - 53
MANUAL TRANSMISSION - NV4500 (Continued)

GEAR CASE
(1) Remove countershaft front bearing cap with
hammer (Fig. 41).
(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 42).
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 43). A small pin punch can be mod-
ified by putting a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 43).
(4) Remove shift lug rail.MAINSHAFT
NOTE: Gear and synchro components can be
installed backwards. Paint or scribe gear and syn-
chro components for installation reference. Then
stack geartrain parts in order of removal.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Place 3-4 gear in a press with support under
3rd gear and Remove 3-4 synchro hub, third gear
stop ring and third gear as an assembly (Fig. 44).
(3) Remove third gear bearing from mainshaft
(Fig. 45).
(4) Remove third gear bearing spacer (Fig. 46).
(5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 46).
(6) Remove second gear thrust washer (Fig. 47).
Note washer notch for locating pin.
Fig. 41 COUNTERSHAFT FRONT BEARING CAP
1 - HAMMER
2 - BEARING CAP
Fig. 42 COUNTERSHAFT FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 43 SHIFT LUG ROLL PIN
1 - PUNCH
2 - 30É BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
21 - 54 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(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.
(23) Remove reverse gear thrust washer (Fig. 60).
(24) Remove reverse gear and synchro components
as assembly (Fig. 61).CAUTION: Do not disassemble synchro compo-
nents unless they are damaged. If synchro sleeve
or struts require service, mark position of sleeve on
hub before removal. Correct sleeve position is
important as sleeve can be installed backwards
causing shift problems.
(25) Remove reverse gear bearing assembly from
mainshaft (Fig. 61).
(26) Remove reverse gear bearing spacer from
mainshaft (Fig. 62).
(27) Remove reverse clutch gear snap ring (Fig.
62). Heavy duty snap ring pliers will be required to
spread the ring far enough to remove it.
Fig. 59 MAINSHAFT REAR BEARING
1-JAWS
2 - COLLAR
3 - FLANGE
4 - MAINSHAFT
5 - PULLER
6 - TIGHTENING WRENCH
7 - HOLDING WRENCH
8 - RODS
Fig. 60 REVERSE GEAR THRUST WASHER
1 - REVERSE GEAR
2 - THRUST WASHER
Fig. 61 REVERSE GEAR, BEARING, AND STOP
RING
1 - FIRST GEAR
2 - REVERSE GEAR ASSEMBLY
3 - BEARING ASSEMBLY
4 - STOP RING
Fig. 62 REVERSE GEAR BEARING SPACER AND
FIRST GEAR SNAP RING
1 - CLUTCH GEAR SNAP RING
2 - REVERSE GEAR BEARING SPACER
DRMANUAL TRANSMISSION - NV4500 21 - 59
MANUAL TRANSMISSION - NV4500 (Continued)

(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 Mopar Loc N' Seal or equiva-
lent to threads of rear bearing plate bolts. Then
install and tighten bearing plate bolts to 23 N´m (200
in. lbs.).
SHIFT LUG AND RAIL
(1) Lubricate shift lug and rail with CastroltSyn-
torq or equivalent.
(2) Insert shift lug rail part way into case.
(3) Install shift lug on rail.
(4) Position shift rail so roll pin notches are
toward outside of case (Fig. 78).
(5) Install roll pin that secures lug to rail (Fig. 78).
MAINSHAFT AND GEARTRAIN
CAUTION: The reverse, 1-2 and 3-4 synchro compo-
nents can be assembled and installed incorrectly.
Follow assembly procedures for component identi-
fication and location.
Lubricate mainshaft bearing surfaces and all bear-
ing assemblies with CastroltSyntorq or with petro-
leum jelly.
(1) Install first snap ring in rear most groove of
mainshaft hub (Fig. 79). This snap ring locates first
gear clutch gear on shaft.NOTE: Four of these snap rings are used to secure
various components on the mainshaft 1-2 synchro
hub. The snap rings are all the same size and are
interchangeable.
(2) Install first gear clutch cone on mainshaft 1-2
synchro hub with recessed side of cone facing front
(Fig. 80). Verify cone is seated against snap ring on
hub.
Fig. 78 SHIFT LUG AND RAIL
1 - NOTCHES (FOR 5TH GEAR SHIFT FORK ROLL PINS)
2 - LUG RAIL
3 - ROLL PIN HOLE
4 - SHIFT LUG
Fig. 79 FIRST GEAR BEARING AND SNAP RING
1 - SNAP RING
2 - FIRST GEAR BEARING
3 - MAINSHAFT SYNCHRO HUB
Fig. 80 FIRST GEAR CLUTCH CONE
1 - MAINSHAFT 1-2 SYNCHRO HUB
2 - FIRST GEAR CLUTCH CONE
21 - 64 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(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 install
remaining gears, snap rings and synchro compo-
nents. Shaft can be supported in gear case or hole
can be cut in workbench to support shaft.
(5) If 1-2 synchro hub and sleeve were disassem-
bled for service, reassemble hub, sleeve, struts and
springs as follows:
(a) Align and install sleeve on hub. Rotate sleeve
until it slides onto hub. Sleeve only fits one way
and will easily slide onto hub when long slot in
sleeve, aligns with long shoulder on hub (Fig. 82).
(b) Place wood blocks under hub that will raise
hub about 3.5 cm (1.375 in.) above surface of work-
bench. Then allow sleeve to drop down on hub (Fig.
83).
(c) Install springs and struts in hub (Fig. 83).
Use lots of petroleum jelly to hold them in place.
Then compress struts with your fingers and move
sleeve upward until struts are started in sleeve.
Verify that struts are engaged in sleeve before pro-
ceeding.
(d) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated
and springs are not displaced during assembly.
Fig. 81 FIRST GEAR CLUTCH CONE SNAP RING
1 - FIRST GEAR CLUTCH CONE
2 - MAINSHAFT 1-2 SYNCHRO HUB
3 - CLUTCH CONE SNAP RING
Fig. 82 1-2 SYNCHRO SLEEVE ON HUB
1 - ALIGN WIDE SLOT IN SLEEVE WITH WIDE SPLINE OF HUB
2 - 1-2 SLEEVE AND HUB
Fig. 83 1-2 SYNCHRO STRUTS AND SPRINGS
1 - WOOD BLOCKS
2 - HUB
3 - SLEEVE
4 - STRUTS AND SPRINGS (4 EACH)
DRMANUAL TRANSMISSION - NV4500 21 - 65
MANUAL TRANSMISSION - NV4500 (Continued)

(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 taper on the sleeve facing for-
ward. (Fig. 85).(8) Install snap ring that secures 1-2 synchro on
mainshaft hub (Fig. 86). Verify snap ring is seated in
groove in mainshaft hub.
(9) Assemble second gear clutch cone, clutch ring
and stop ring (Fig. 87).
Fig. 84 FIRST GEAR STOP RING IN SYNCHRO HUB
Fig. 85 1-2 SYNCHRO
1 - MAINSHAFT HUB
2 - 1-2 SYNCHRO ASSEMBLY
3 - TAPERED SIDE OF SLEEVE
Fig. 86 1-2 SYNCHRO SNAP RING
1 - SYNCHRO SNAP RING
2 - 1-2 SYNCHRO ASSEMBLY
3 - MAINSHAFT HUB
Fig. 87 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - STOP RING
2 - CLUTCH RING
3 - CLUTCH CONE
21 - 66 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)

(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 blade
screwdriver to work snap ring into hub groove as
shown. Verify snap ring is seated in mainshaft
groove.
NOTE: If snap ring will not fit in groove, clutch cone
is slightly misaligned.(12) Install second gear bearing on mainshaft (Fig.
90).
(13) Install second gear on mainshaft and bearing.
Rotate gear until tabs of second gear clutch ring are
seated in tab slots in gear (Fig. 91).
Fig. 88 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - CLUTCH CONE
2 - STOP RING
3 - CLUTCH RING
Fig. 89 SECOND GEAR CLUTCH CONE SNAP RING
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
4 - SECOND GEAR CLUTCH CONE
Fig. 90 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
Fig. 91 SECOND GEAR
1 - SECOND GEAR
2 - CLUTCH RING TABS
3 - TAB SLOTS (IN GEAR)
DRMANUAL TRANSMISSION - NV4500 21 - 67
MANUAL TRANSMISSION - NV4500 (Continued)