Dodge ram truck 3500 1996 Service Manual page 1450

21 - 60 NW4II0 MANUAL TRANSMISSION
e n
REMOVAL AND INSTALLATION (Continued)
(3) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(4) Verify that 1-2 and 3-4 synchro sleeves are i n
neutral position. Also verify that forks in shift cover
are in neutral position.
(5) Align and install shift cover (Fig. 22). I f cover
will not seat, i t is either not aligned on gear case
dowels, or shift forks are not aligned with sleeves
and shift lug.
(6) Apply Mopar Lock N ' Seal or Loctite 242 to
threads of shift cover bolts.
(7) Install and tighten shift cover bolts to 27-31
N-m (216-276 in. lbs.) torque.
(8) Install backup light switch in cover. Apply
sealer to switch threads before installation and
tighten switch to 22-34 N-m (193-265 in. lbs.).
(9) Install vent assembly, i f removed. Apply an
adhesive/sealer to vent tube to help secure i t i n cover.
D I S A S S E M B L Y AMB ASSEMBLY
EXTENSION/ADAPTER HOUSING
REMOVAL
(1) Remove bolts attaching extension/adapter hous­
ing to gear case (Fig. 23). Use 10 mm, 12 point socket
to remove housing bolts. Loosen bolts 4-5 threads
with socket and ratchet first. An air wrench can then
be used to complete removal but only after bolts are
loose.
CAUTION: Spline head bolts are used to attach the
extension or adapter housing to the gear case. The
bolt splines are easily damaged if the wrong tool is
used to loosen and remove them. Use a 10 mm, 12
point socket or box end wrench only.
(2) Remove extension/adapter housing (Fig. 24).
Tap housing with rubber mallet to loosen it. Then
break sealer bead with putty knife and work housing
off alignment dowels with two pry tools. One align­
ment dowel is in case. Other dowel is in housing.
GEAR
CASE J9221-85
Fig. 24 Extension/Adapter Housing Removal/
Installation
(3) Remove spline seal from end of mainshaft (Fig.
25). The seal can be reused or discarded as
desired. The seal is not an essential part and
can be reused or discarded as desired. The seal
is mainly used to prevent lubricant loss during
shipping and does not have to be replaced if
damaged.
Fig. 25 Mainshaft Spline Seal
Fig. 23 Extension/Adapter Housing Bolts