Dodge ram truck 3500 1996 Service Manual page 1398

21 - 8 NV3500 MANUAL TRANSMISSION
BR
REMOVAL AND INSTALLATION (Continued)
Fig. 9 Removing Shift Lever Extension With Tooi 6783
(3) Mount transmission on jack. Secure transmis­
sion to jack with safety chains.
(4) Lubricate transmission input shaft pilot hub
and splines with light coat of Mopar high tempera­
ture grease.
(5) Align transmission input shaft with release
bearing and clutch disc. Then slide clutch housing
into place on engine block.
(6) Install and tighten transmission attaching bolts
to 54-61 N-m (40-45 ft. lbs.) torque. Be sure housing is
fully seated before tightening bolts. I f equipped, install
dust cover after tightening housing bolts.
(7) Fill transmission with Mopar lubricant, P/N
4761526. Correct fill level is to bottom edge of fill
plug hole.
(8) Connect backup light switch wires.
(9) Connect transmission harnesses and vent line
to retainer clips on housing.
(10) Install center crossmember. Tighten cross-
member-to-frame bolts to 67 N-m (50 ft. lbs.) torque.
(11) Tighten crossmember-to-support bracket nuts
to 54-61 N-m (40-45 ft. lbs.) torque.
(12) Install slave cylinder in transmission clutch
housing. Tighten cylinder attaching nuts to 23 N-m
(200 in. lbs.) torque.
(13) Remove jack used to support transmission.
(14) Install strut bolts/nuts, i f removed.
(15) Install transfer case. Align and position trans­
fer case with transmission jack or aid of helper. Tilt
case upward and work into position on transmission
mounting studs.
(16) Install and tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque.
(17) Install and connect transfer case shift linkage.
(18) Connect vehicle speed sensor harness wire to
sensor.
(19) Align and connect exhaust system compo­
nents. Be sure exhaust components are clear of all
chassis and driveline components.
(20) Align and install front and rear propeller
shafts. Tighten U-joint clamp bolts to 19 N-m (170 in.
lbs.) torque.
(21) Verify that all linkage components, hoses and
electrical wires have been connected.
(22) Check transfer case fluid level. Add Mopar
Dexron I I , or ATF Plus i f necessary. Correct level is
to edge of fill plug hole. Be sure transfer case is level
before checking or adding fluid.
(23) Check and adjust transfer case shift linkage i f
necessary.
(24) Install transfer case skid plate, i f equipped.
(25) Fill transmission with Mopar lubricant, P/N
4761526. Correct fill level is to bottom edge of fill
plug hole.
(26) Install crankshaft position sensor.
(27) Remove any remaining support stands and
lower vehicle.
(28) Connect battery negative cable.
(29) Apply Mopar Gasket Maker, or Loctite 518 to
mounting surfaces of shift tower, isolator plate, and
lever mounting surface on transmission front housing.
(30) Install isolator plate on shift tower, or rear
case. Then install shift tower and lever assembly.
Tighten shift tower bolts to 7-10 N-m (5-7 ft. lbs.)
torque. Note that isolator plate is one way fit. Nar­
row side goes toward driver side of transmission.
(31) I f shift lever extension was removed from
shift lever, reinstall with Tool 6783 as follows:
(a) Reposition upper jaw of Remover/Installer
Tool 6783 above flange on lever extension (Fig.
10). 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.
(c) Remove special tool.
(32) Install shift boot and bezel.
D I S A S S E M B L Y A N D A S S E M B L Y
TRANSMISSION ^
The following disassemble and assemble procedures
require removing the transmission from the vehicle.