Dodge ram truck 3500 1996 Service Manual page 1444

21 - 54 NV4500 MANUAL TRANSMISSION
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B R
R E M O V A L A N D I N S T A L L A T I O N
TRANSMISSION—2WD
REMOVAL
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on lever extension.
(4) Remove shift lever extension with Remover/In­
staller Tool 6783 as follows:
(a) Scribe mark position of extension on shank of
shift lever.
(b) Position notched, lower end of tool just under
square shank of shift lever (Fig. 10).
(c) Position tool upper jaws under flange on
shift lever extension (Fig. 10).
(d) Tighten tool screw to pull extension off
square shank of shift lever.
(e) Remove lever extension and tool.
Fig. 10 Removing Shift Lever Extension With Tool
6783
(5) Raise and support vehicle.
(6) Mark propeller shaft and axle yokes for align­
ment reference. Use paint, scriber, or chalk to mark
yokes.
(7) Remove U-joint clamp strap screws and remove
clamps.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system Y-pipe.
(10) Disconnect wires at speed sensor and backup
light switch.
(11) Support engine with adjustable safety stand
and wood block.
(12) I f transmission is to be disassembled for
repair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission.
(13) Remove bolts/nuts attaching transmission to
rear mount.
(14) Support transmission with a transmission
jack. Secure transmission to jack with safety chains.
(15) Remove rear crossmember.
(16) Remove bolts attaching clutch slave cylinder
to clutch housing. Then move cylinder aside for work­
ing clearance.
(17) Remove transmission harness wires from clips
on transmission shift cover.
(18) Remove bolts attaching transmission to clutch
housing.
(19) Slide transmission and jack rearward until
drive gear clears clutch housing.
(20) Lower transmission jack and remove trans­
mission from under vehicle.
(21) I f transmission will be overhauled, clean
transmission exterior with solvent or with steam
gun.
TRANSMISSION INSTALLATION—2WD
(1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com­
ponents:
• drive gear splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bearing
• release bearing bore
• release fork
• release fork ball stud
• propeller shaft slip yoke
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans­
mission under vehicle.
(4) Raise transmission until drive gear is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start drive
gear in release bearing, clutch disc and pilot bushing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after drive gear has entered clutch disc.
(7) Install and tighten transmission-to-clutch
housing bolts to 108 N-m (80 ft. lbs.) torque.
(8) Install clutch slave cylinder.