Dodge ram truck 3500 1996 Service Manual page 1414

21 - 24 NV3500 MANUAL TRANSMISSION
B R
D I S A S S E M B L Y
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A S S E M B L Y
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(12) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 71). Be
sure bearing is properly seated after installation.
Fig. 71 installing Fifth Gear Bearing
(13) Install fifth gear on shaft and onto bearing
(Fig. 72).
Fig. 72 Fifth Gear Installation
(14) Install output shaft bearing with shop press
and suitable size pipe tool (Fig. 73).
(15) Install output shaft bearing snap ring (Fig.
74) . Use heavy duty snap ring pliers and spread snap
ring only enough to install it. Be sure snap ring is
completely seated in shaft groove before proceeding.
(16) Turn output shaft over so it is supported on
press blocks by output shaft bearing (Fig. 75).
Remainder of geartrain can now be installed on shaft
while i t is still mounted in shop press.
(17) Install first gear bearing on output shaft (Fig.
75) . Be sure bearing is seated on shaft shoulder and
is properly joined.
(18) Install first gear on shaft and over bearing
(Fig. 76). Make sure bearing synchro cone is facing
up as shown.
Fig. 73 Output Shaft Bearing Installation
Fig. 74 installing Output Shaft Bearing Snap Ring
(19) Install first speed synchro ring (Fig. 77).
(20) Assemble 1-2 synchro hub sleeve, springs,
struts and detent balls.
CAUTION: The 1-2 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the hub has a small diameter shoulder
around the hub bore. Make sure this side of the hub
faces the forward end of the output shaft. In addi­
tion, one side of the synchro sleeve is marked First
Gear Side. Be sure this side of the sleeve will face
the first gear after installation.
(21) Start 1-2 synchro assembly on shaft by hand
(Fig. 78). Be sure synchro sleeve is properly posi-