Dodge RAM TRUCK 1500 1995 Service Manual page 1358

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NW451I MANUAL TRANSMISSION 21 - 71
LEGEND FOR MAINSHAFT GEARTRAIN
1. MAINSHAFT
2. FIRST GEAR BEARING
3. FIRST GEAR
4. CLUTCH GEAR
5. SYNCHRO STOP RING
6. FIRST GEAR SNAP RING
7. REVERSE GEAR BEARING SPACER
8. REVERSE GEAR BEARING
9. REVERSE SYNCHRO SLEEVE
10. SYNCHRO STRUTS AND SPRINGS (3 EACH)
11. REVERSE GEARLINES
12. THRUST WASHER
13. THRUST WASHER LOCATING PIN
14. MAINSHAFT REAR BEARING
15. MAINSHAFT REAR BEARING CUP
16. MAINSHAFT END PLAY SHIMS
17. MAINSHAFT REAR BEARING PLATE
18. MAINSHAFT FIFTH GEAR
19. THRUST WASHER
20. FIFTH GEAR NUT
21. MAINSHAFT SPLINE SEAL
22. CLUTCH GEAR SNAP RING
23. FIRST SPEED CLUTCH GEAR
24. FIRST GEAR SYNCHRO CLUTCH RING
TRANSMISSION ASSEMBLY AND ADJUSTMENT
Assembly Information
Gaskets are not used in the NV4500 transmis­
sion. Use Mopar Gasket Maker, silicone adhe­
sive/sealer, or Loctite 518 on all gear case and
extension housing sealing surfaces.
Adjustment Specifications
• Countershaft End Play: 0.051-0.15 mm (0.002-
0.006 in.)
SPECIAL TOOL SPECIAL TOOL
C-4171 6061-1
Fig. 84 Installing Countershaft Front Bearing Cup
25. SYNCHRO HUB SNAP RING
26. FIRST GEAR SYNCHRO STOP RING
27. 1-2 SYNCHRO SLEEVE
28. SYNCHRO STRUTS AND SPRINGS (4 EACH)
29. 1 -2 SYNCHRO HUB (INC. RETAINER SPRINGS AND WEIGHTS)
30. SYNCHRO HUB SNAP RING
31. SECOND GEAR SYNCHRO STOP RING
32. SECOND SPEED CLUTCH GEAR
33. SECOND GEAR SYNCHRO CLUTCH RING
34. CLUTCH GEAR SNAP RING
35. SECOND GEAR BEARING
36. SECOND GEAR
37. THRUST WASHER AND LOCATING PIN
38. THRUST WASHER SNAP RING
39. THIRD GEAR BEARING SPACER
40. THIRD GEAR
41. THIRD GEAR BEARING ASSEMBLIES (2)
42. THIRD GEAR SYNCHRO STOP RING
43. 3-4 SYNCHRO SLEEVE
44. SYNCHRO STRUTS AND SPRINGS (3 EACH)
45. 3-4 SYNCHRO HUB
46. FOURTH GEAR SYNCHRO STOP RING
47. FOURTH SPEED CLUTCH GEAR
48. DRIVE GEAR THRUST BEARING
J9321-98
• Mainshaft End Play: 0.051-0.15 mm (0.002-0.006
in.)
GEAR CASE ASSEMBLY
(1) Install countershaft front bearing cup in case
with Tool Handle C-4171 and Installer Tool 6061-1 or
C-4340 (Fig. 84).
(2) Install new bushings in shift lug rail bores with
Tool 6456 (Fig. 85). Seat bushings flush with bores.
Fig. 85 Installing Shift Lug Rail Bushings
(3) If case magnet was removed, install and secure
magnet in clip at bottom of case (Fig. 86).
COUNTERSHAFT AND REVERSE IDLER GEAR
INSTALLATION
(1) Install front bearing on countershaft with In­
staller Tool 6446 (Fig. 87).
(2) Lubricate countershaft front bearing cup and
cone with petroleum jelly.
(3) Position gear case on end with rear of case fac­
ing up (Fig. 88).