2003 DODGE RAM app

(9) Apply Mopar Gasket Maker or equivalent to
housing bolt threads, bolt shanks and under bolt
heads (Fig. 95).
(10) Start first two bolts in retainer (Fig. 96). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(11) Remove Alignment Pin 8120 and install last
retainer bolt (Fig. 96).
(12) Tighten retainer bolts to 30-35 N´m (22-26 ft.
lbs.).ADAPTER HOUSING - 4WD
NOTE: Transmission shift components must be in
Neutral to prevents damaging to the synchro and
shift components when installing the housings.
(1) Install rear bearing in adapter housing. Use
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 97).
(3) Apply Mopar Gasket Maker or equivalent to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 95).
(4) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(5) Install countershaft rear bearing in bearing
race (Fig. 93).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(6) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(7) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in adapter housing (Fig. 93).
Fig. 95 HOUSING BOLTS
1 - GASKET MAKER
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 96 Alitgnment Pin And Retainer Bolts
1 - BEARING RETAINER BOLT
2 - ALIGNMENT PIN
Fig. 97 ADAPTER HOUSING
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 31
MANUAL TRANSMISSION - NV3500 (Continued)

(4) Assemble shift shaft shift lever and bushing
(Fig. 102). Verify slot in bushing is facing up and roll
pin hole for lever is aligned with hole in shaft.
(5) Install assembled lever and bushing on shift
shaft (Fig. 103).
(6) Slide shift shaft through 1-2 and fifth-reverse
fork and into shift lever opening in rear housing (Fig.
104).
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 105).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Both shaft roll pins can be installed
when the shaft is 180É off. If this occurs, the trans-mission will have to be disassembled again to cor-
rect shaft alignment.
(9) Select correctnewroll pin for shift shaft lever
(Fig. 106). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
Fig. 102 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 103 SHIFT SHAFT LEVER AND BUSHING
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 104 SHAFT LEVER OPENING
1 - SHIFT SHAFT
Fig. 105 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 106 ROLL PIN IDENTIFICATION
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
DRMANUAL TRANSMISSION - NV3500 21 - 33
MANUAL TRANSMISSION - NV3500 (Continued)

(15) Verify that notches in shift fork arms are
aligned (Fig. 111). Realign arms if necessary.
(16) Rotate shift lever and bushing downward to
expose detent bore in the lever.
(17) Install detent spring then the ball into the
detent bore (Fig. 112) and hold the ball in the lever.
Then rotate the lever upward into the fork arm
notches.
NOTE: Verify detent ball is seated in the fork arms
before proceeding.
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) If previously removed, install input shaft bear-
ing in front housing bore (Fig. 113). Install snap ringand use plastic mallet to seat bearing. Bearing goes
in from front side of housing only.
(2) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 113). Large diameter side of
bearing cage goes toward countershaft (Fig. 114).
Small diameter side goes toward bearing race in
housing.
(3) Reach into countershaft front bearing with fin-
ger and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place during housing installation.
(4) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
Fig. 111 SHIFT LEVER POSITION
1 - SHIFT FORK ARMS
2 - DETENT BORE
Fig. 112 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
Fig. 113 INPUT SHAFT & COUNTERSHAFT
BEARING
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 35
MANUAL TRANSMISSION - NV3500 (Continued)

(5) Apply 1/8 in. wide bead of Mopar Gasket
Maker or equivalent to mating surfaces of front and
rear housings (Fig. 115).
(6) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(7) Work front housing downward onto geartrain
until seated on rear housing.
CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(9) Place transmission in horizontal position.
(10) Apply Mopar Gasket Maker or equivalent to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 116).
(11) Install and start housing attaching bolts by
hand (Fig. 116). Then tighten bolts to 34 N´m (25 ft.
lbs.).(12) Install shift shaft bushing lock bolt (Fig. 117).
Apply Mopar Gasket Maker or equivalent to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubricate then install shift shaft detent
plunger in housing bore. Lubricate plunger with
semi-synthetic/synthetic grease. Verify plunger is
fully seated in detent notch in shift shaft.
(14) Install detent spring inside plunger.
(15) Install detent plug in end of Installer 8123.
Position plug on detent spring and compress spring
until detent plug pilots in detent plunger bore. Drive
detent plug into transmission case until plug seats.
Fig. 115 SEAL HOUSINGS
1 - HOUSING FLANGE SURFACE
2 -GASKET MAKER
Fig. 116 HOUSING BOLTS
1 - HOUSING BOLTS
Fig. 117 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
21 - 36 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(16) Install backup light switch (Fig. 118).
(17) Install input shaft snap ring (Fig. 119).
(18) Installnewoil seal in front bearing retainer
with Installer 6448 (Fig. 120).(19) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
121).
(20) Align and install front bearing retainer over
input shaft and onto housing mounting surface (Fig.
122). Verify bolt holes are aligned before seating
retainer.
CAUTION: Be sure sealer does not get into the oil
feed hole in the transmission case or bearing
retainer.
Fig. 118 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 119 SHAFT SNAP RING - TYPICAL
1 - INPUT SHAFT SNAP RING
Fig. 120 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - FRONT BEARING RETAINER
Fig. 121 SEAL BEARING RETAINER - TYPICAL
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
Fig. 122 INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
3 - BEARING RETAINER
DRMANUAL TRANSMISSION - NV3500 21 - 37
MANUAL TRANSMISSION - NV3500 (Continued)

(21) Install and tighten bearing retainer bolts to
7-10 N´m (5-7 ft. lbs.) (Fig. 123).
SHIFT TOWER AND LEVER
(1) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(2) Shift the transmission into third gear.
(3) Align and install shift tower and lever assem-
bly (Fig. 124). Be sure shift ball is seated in socket
and the offset in the tower is toward the passenger
side of the vehicle before installing tower bolts.
(4) Install shift tower bolts (Fig. 125) and tighten
bolts to 8.5 N´m (75.2 in. lbs.).
(5) Fill transmission to bottom edge of fill plug
hole with lubricant.
(6) Install and tighten fill plug to 34 N´m (25 ft.
lbs.).(7) Check transmission vent. Be sure vent is open
and not restricted.
INSTALLATION
NOTE: If a new transmission is being installed, use
all components supplied with the new transmission.
For example, if a new shift tower is supplied, do not
re-use the original shift tower.
(1) Clean transmission front housing mounting
surface.
(2) Apply light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces (Fig.
126) of following components:
²release fork ball stud.
²release bearing slide surface.
²input shaft splines.
²release bearing bore.
²propeller shaft slip yoke.
(3) Support and secure transmission to jack.
(4) Raise and align transmission input shaft with
clutch disc, then slide transmission into place.
(5) Verify front housing is fully seated. Install
transmission bolts without washers and tighten bolts
into the engine to 41 N´m (30 ft. lbs.). Tighten the
bolts with washers into the transmission to 68 N´m
(50 ft. lbs.) (Fig. 127).
(6) Install rear crossmember and tighten nuts to
102 N´m (75 ft. lbs.).
(7) Install transmission rear mounting bolts and
tighten to 68 N´m (50 ft. lbs.).
(8) Install front dust shield.
(9) Install structural dust cover and tighten the
bolts to 73 N´m (54 ft. lbs.).
(10) Install starter motor.
(11) Install suspension crossmember and tighten
nuts to 102 N´m (75 ft. lbs.).
Fig. 123 BEARING RETAINER BOLTS - TYPICAL
1 - RETAINER BOLTS
2 - RETAINER
Fig. 124 SHIFT TOWER
1 - SHIFT TOWER
2 - SHAFT SOCKET
3 - SHIFT BALL
Fig. 125 SHIFT TOWER BOLTS
1 - SHIFT TOWER AND LEVER ASSEMBLY
21 - 38 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

MANUAL TRANSMISSION - NV4500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV4500
DESCRIPTION.........................42
OPERATION...........................42
DIAGNOSIS AND TESTING................43
REMOVAL.............................43
DISASSEMBLY.........................44
CLEANING............................60
INSPECTION..........................60
ASSEMBLY............................61
INSTALLATION.........................77
SPECIFICATIONS.......................79
SPECIAL TOOLS.......................79ADAPTER HOUSING SEAL
REMOVAL.............................83
INSTALLATION.........................83
EXTENSION HOUSING SEAL
REMOVAL.............................83
INSTALLATION.........................83
SHIFT MECHANISM
REMOVAL.............................84
INSTALLATION.........................85
SHIFT COVER
REMOVAL.............................86
INSTALLATION.........................86
MANUAL TRANSMISSION -
NV4500
DESCRIPTION
The NV4500 is a five speed constant mesh manual
transmission. All gear ranges including reverse are
synchronized. Fifth gear is an overdrive range. The
transmission has a cast iron gear case and aluminum
shift cover.
Two versions are used, a standard duty for 5.7L
applications and a heavy duty for V10 and Cummins
diesel applications. Main difference is a larger diam-
eter input shaft, for the heavy duty model.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Roller
bearings in the drive gear support the forward end of
the mainshaft. The mainshaft gears are all supported
on caged type roller bearings. Drive gear thrust reac-
tion is controlled by a needle type thrust bearing.
The bearing is located at the forward end of the
mainshaft.
The transmission is a top loader style. The shift
lever is located in a shifter tower which is bolted to
the shift cover and operates the shift forks and rails
directly. The shift forks and rails are all located
within the aluminum cover which is bolted to the top
of the gear case.
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 1).
The tag provides the transmission model number,
build date and part number. Be sure to reinstall the
I.D. tag if removed during service. The information
on the tag is essential to correct parts ordering.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point all the transmission gears
are spinning.
Fig. 1 IDENTIFICATION TAG LOCATION
1 - PTO COVER
2 - I.D. TAG
21 - 42 MANUAL TRANSMISSION - NV4500DR

(2) Remove extension/adapter housing (Fig. 9).
There is one alignment dowel in the gear case and
one in the extension/adapter housing.
(3) Remove rubber spline seal from end of main-
shaft (Fig. 10). The seal is used to prevent lubricant
loss during shipping and does not have to be replaced
if damaged.
FIFTH GEAR NUT
(1) Remove extension/adapter housing.
(2) Loosen fifth gear clamp nut clamping screw
approximately 1 1/2 turns.
(3) Install Wrench 6743 on fifth gear nut (Fig. 11).
NOTE: Wrench only fits one way on nut. Make sure
wrench is fully engaged in nut slots and is not
cocked.
(4)
Install Socket 6993 4X2 or Socket 6984 4X4 with
breaker bar to hold mainshaft and remove fifth gear nut.
NOTE: Wedge breaker bar handle against workbench.
Purpose of socket wrench and breaker bar is to pre-
vent mainshaft from turning while nut is loosened.
(5) Remove fifth gear nut, then remove belleville
washer from mainshaft.
FIFTH GEAR
(1) Remove fifth gear shift fork roll pins (Fig. 12).
Drive roll pins out from the bottom of fork.
Fig. 9 EXTENSION/ADAPTER HOUSING
1 - GEAR CASE
2 - EXTENSION HOUSING
Fig. 10 MAINSHAFT SPLINE SEAL
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 11 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SPLINE SOCKET
Fig. 12 FIFTH GEAR SHIFT FORK ROLL PINS
1 - ROLL PINS
2 - FIFTH GEAR SHIFT FORK
21 - 46 MANUAL TRANSMISSION - NV4500DR
MANUAL TRANSMISSION - NV4500 (Continued)