Dodge RAM TRUCK 1500 1995 Service Manual page 1336

B R NV4500 MANUAL TRANSMISSION 21 - 53
(18) Move transfer case forward and seat it on
adapter.
(19) Install and tighten transfer case attaching
nuts. Tighten nuts to 41-47 N-m (30-35 ft. lbs.) If case
has 3/8 studs, or 30-41 N-m (22-30 ft. lbs.) If case has
5/16 studs.
(20) Connect transfer case shift lever to range le­
ver on transfer case.
(21) Align and connect propeller shafts. Tighten U-
joint clamp strap bolts to 19 N-m (170 in. lbs.)
torque.
(22) Fill transmission with required lubricant.
Check lubricant level in transfer case as well and
add lubricant If necessary,
(23) Install transfer case skid plate and crossmem­
ber. Tighten attaching bolts/nuts to 41 N-m (30 ft.
lbs.) torque.
(24) Install exhaust system components.
(25) Lower vehicle.
(26) 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.
(27) Install shift lever boot and bezel.
(28) Connect battery negative cable.
TRANSMISSION DISASSEMBLY AND OVERHAUL
SHIFT COVER REMOVAL
(1) Remove shift cover bolts (Fig. 1).
Fig. 1 Shift Cover Bolt Removal/Installation
(2) Loosen shift cover with pry tool. To avoid dam­
aging cover seal surface, insert pry tool only in slots
provided in cover (Fig. 2).
(3) Raise cover enough to disengage it from align­
ment dowels in gear case (Fig. 3).
SHIFT
COVER
SLOT
Fig. 2 Loosening Shift Cover
(4) Raise front of shift cover and lift cover up and
off gear case (Fig. 3).
(5) Set cover assembly aside for inspection. If cover
components are damaged, refer to shift cover service
information.
Fig. 3 Shift Cover Removal/Installation
EXTENSION/ADAPTER HOUSING REMOVAL
(1) Remove bolts attaching extension/adapter hous­
ing to gear case (Fig. 4). Use 10 mm, 12 point socket
to remove housing bolts. Loosen bolts 4-5 threads
with socket and ratchet first. An air wrench can then
be used to complete removal but only after bolts are
loose.
C A U T I O N : Spline head bolts are used to attach the
extension or adapter housing to the gear case. The
bolt splines are easily damaged if the wrong tool is
used to loosen and remove them. Use a 10 mm, 12
point socket or box end wrench only.
(2) Remove extension/adapter housing (Fig. 5). Tap
housing with rubber mallet to loosen it. Then break
sealer bead with putty knife and work housing off