Dodge ram truck 3500 1996 Service Manual page 1446

21 • 56 NV4500 MANUAL TRANSMISSION
BR
REMOVAL AND INSTALLATION (Continued)
(8) Mark propeller shafts and yokes for assembly
reference.
(9) Disconnect propeller shafts and remove propel­
ler shafts.
(10) Disconnect and remove exhaust system Y-pipe.
Then disconnect and lower remaining exhaust pipes
for clearance as necessary.
(11) Support engine with adjustable safety stand.
(12) Disconnect speed sensor wires and disconnect
speedometer cable, i f equipped.
(13) Disconnect backup light switch wires.
(14) Disconnect transfer case shift linkage at
transfer case range lever. Then remove transfer case
shift mechanism from transmission (Fig. 13).
TRANSMISSION
J9421-258
TRANSFER CASE
SHIFT MECHANISM '
Fig. 13 Transfer Case Shift Mechanism
(15) Remove bolts/nuts attaching transmission to
rear support.
(16) Remove crossmember bolts/nuts and remove
crossmember.
(17) Support transfer case with transmission jack.
Secure transfer case to jack with safety chains.
(18) Remove transfer case attaching nuts.
(19) Move transfer case rearward until input gear
clears transmission mainshaft.
(20) Lower transfer case assembly and move it
from under vehicle.
(21) I f transmission is being removed for repair,
remove drain bolt at bottom of PTO cover and drain
lubricant from transmission.
(22) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(23) Remove transmission harness from retaining
clips on transmission shift cover.
(24) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(25) Remove rear crossmember.
(26) Remove clutch slave cylinder splash shield, i f
equipped.
(27) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever. This
reduces pressure on lever and release bearing mak­
ing transmission removal/installation easier. Cylinder
does not have to be removed completely.
(28) Remove bolts attaching transmission to clutch
housing.
(29) Move transmission rearward until drive pin­
ion clears clutch disc and release bearing.
(30) Lower transmission and remove i t from under
vehicle.
(31) I f transmission will be overhauled, thoroughly
clean transmission exterior with solvent or steam
gun.
TRANSMISSION INSTALLATION—4WD
(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 PTO cover bottom
drain bolt then install bolt in case.
(3) Mount transmission on jack and position trans­
mission under vehicle. Secure transmission to jack
with safety chains.
(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 and clutch disc.
(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) Connect speed sensor and backup light switch
wires.
(9) Position transmission harness wires in clips on
shift cover.
(10) Tighten slave cylinder attaching nuts and
install slave cylinder shield, i f equipped.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install transfer case shift mechanism on
transmission (Fig. 13).
(13) Install rear crossmember.
(14) Remove transmission jack and engine support
fixture.
(15) Install transfer case on transmission jack.
Secure transfer case to jack with safety chains.