Dodge RAM TRUCK 1500 1995 Service Manual page 1334

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NV4500 MANUAL TRANSMISSION 21 - 51
(19) Slide transmission and jack rearward until
drive gear clears clutch housing.
(20) Lower transmission jack and remove trans­
mission from under vehicle.
(21) If transmission will be overhauled, clean
transmission exterior with solvent or with steam
gun.
TRANSMISSION INSTALLATION (2-WHEEL DRIVE)
(1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com­
ponents:
• drive gear splines and pilot bearing hub
• release bearing slide surface of front retainer
© pilot bearing
• release bearing bore
• release fork
• release fork ball stud
© propeller 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 drive gear is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start drive gear
in release bearing, clutch disc and pilot bushing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after drive gear has entered clutch disc.
(7) Install and tighten transmission-to-clutch hous­
ing bolts to 108 N-m (80 ft. lbs.) torque.
(8) Install clutch slave cylinder.
(9) Connect speed sensor and backup light switch
wires.
(10) Fill transmission with recommended lubri­
cant. Correct fill level is bottom edge of fill plug hole.
(11) Position transmission harness wires in clips
on shift cover.
(12) Install transmission mount on transmission or
rear crossmember.
(13) Install rear crossmember.
(14) Remove transmission jack and engine support
fixture.
(15) Align and connect propeller shaft.
(16) Lower vehicle.
(17) Install lever extension on shift lever with Tool
6783 as follows:
(a) Reposition upper jaw of Remover/Installer
Tool 6783 above flange on lever extension (Fig. 6).
Tool will now be used to press extension back onto
shift lever.
(b) Tighten tool screw to press extension back
onto lever. Press extension to scribe mark made
during removal. A 3-5 mm (0.12 - 0.20 in.) space
should exist between shift lever isolator and top
edge of stub shaft and tool lower jaw.
(c) Remove special tool.
Fig. 6 Installing Shift Lever Extension With Tool
8783
(18) Install shift boot and bezel.
(19) Connect battery negative cable.
TRANSMISSION REMOVAL (4-WHEEL DRIVE)
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift lever boot and bezel.
(4) Remove shift lever extension with Remover/In­
staller Tool 6783 as follows:
(a) Scribe mark position of extension on shank of
shift lever.
(b) Position notched, lower end of tool just under
square shank of shift lever (Fig. 5).
(c) Position tool upper jaws under flange on
shift lever extension (Fig. 5).
(d) Tighten tool screw to pull extension off
square shank of shift lever.
(e) Remove lever extension and tool.
(5) Raise vehicle.
(6) Remove skid plate if equipped.
(7) If transmission will be disassembled for repair,
remove drain bolt at bottom of PTO cover and drain
lubricant from transmission.
(8) Mark propeller shafts and yokes for assembly
reference.