Dodge RAM TRUCK 1500 1995 Service Manual page 1375

21 - 92 NV4500 MANUAL TRANSMISSION
B R
GEAR
CASE J9221-85
Fig. 162 installing Extension/Adapter Housing
(2) Apply Mopar Gasket Maker, or Loctite 518 to
sealing surface of shift cover or gear case. Do not
over-apply sealer material. Excess can be squeezed
into gear case and could block lubricant feed holes in
time.
(3) Lubricate synchro sleeves with lubricant. Then
apply light coat of petroleum jelly to shift fork con­
tact surfaces.
(4) Verify that 1-2 and 3-4 synchro sleeves are in
neutral position. Also verify that forks in shift cover
are in neutral position.
(5) Align and install shift cover (Fig. 163). If cover
will not seat, it is either not aligned on gear case
dowels, or shift forks are not aligned with sleeves
and shift lug.
(6) Apply Mopar Lock N T Seal or Loctite 242 to
threads of shift cover bolts.
SHIR
Fig. 163 Installing Shift Cover Assembly
(7) Install and tighten shift cover bolts to 30 N-m
(265 in. lbs.) torque.
(8) Install backup light switch and vent in shift
cover. Apply sealer to switch threads before installa­
tion and tighten switch to 30 N-m (265 in. lbs.).
(9) On 2-wheel drive models, install and index
speedometer adapter in extension housing.
(10) Install and tighten drain bolt (at bottom of
PTO cover).
(11) Fill transmission to bottom edge of fill plug
hole with Mopar Manual Transmission Lubricant,
P/N 4637579.
(12) Install and tighten fill plug to 40 N-m (30 ft.
lbs.) torque.
SHIFT COVER SERVICE
The only serviceable shift cover components are:
• fifth-reverse shift fork pads
• reverse inhibitor
• vent components
• backup light switch
• expansion plugs
• shift lever components
The shift cover, shift forks, shift rails and detent
components are not serviced individually. The cover
must be replaced as an assembly if the cover, or any
shift components are worn or damaged.
Shift Cover Inspection
Inspect the cover and shift components whenever
the cover is removed from the gear case. Or, when­
ever diagnosis indicates inspection is necessary.
Check the forks for wear, distortion, cracks, or be­
ing loose on the shift rails. Also check fit of the shift
rails in the cover. Replace the cover assembly if the
rails are loose in the cover bores.
Inspect and replace the pads on the fifth-reverse
shift fork if worn. The reverse inhibitor should also
be replaced if worn, or faulty. The expansion plugs at
the rear of the cover can be replaced if loose or leak­
ing.