Dodge ram truck 3500 1996 Service Manual page 1452

21 - 62 NV4500 MANUAL TRANSMISSION
mm
DISASSEMBLY A N D ASSEMBLY (Continued)
(6) Clean mating surfaces of extension/adapter
housing and gear case with a wax and grease
remover.
(7) Check alignment dowels in gear case and hous­
ing or adapter. Be sure dowels are in position and
seated.
(8) Apply Mopar Gasket Maker to gear case and
housing mating surfaces.
(9) Align and install extension/adapter housing on
gear case (Fig. 31).
EXTENSION
HOUSING
GEAR
CASE
J9221-85
Fig. 31 installing Extension/Adapter Housing
(10) Apply Mopar Lock W Seal or Loctite 242 to
threads of extension/adapter housing bolts.
(11) Install and tighten housing bolts to 54 N-m
(40 ft. lbs.) torque. Use a twelve point 1 0 mm
socket, a ratchet wrench and necessary exten­
sions to install bolts. Do not use any other type
of socket and do not use an impact wrench.
Splines on bolt heads can be damaged if impact
wrench or wrong type of socket is used for
tightening purposes.
TRANSMISSION
REMOVING COUNTERSHAFT
FIFTH
GEAR
(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 32).
(2) Remove roll pins that secure countershaft fifth
gear shift fork to shift rail with pin punch (Fig. 33).
Roll pins are driven out from bottom of fork
and not from top.
(3) Remove shift fork and fifth gear components as
assembly. Rotate mainshaft as needed to allow coun­
tershaft fifth gear to clear mainshaft fifth gear.
REMOVING COUNTERSHAFT FIFTH GEAR
COMPONENTS INDIVIDUALLY
(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 32).
CLUTCH
GEAR
RING
FIFTH
SYNCHRO
CLUTCH
GEAR
J9221-89
Fig. 32 Removing Countershaft Fifth Speed Clutch
Gear Snap Ring
PIN
PUNCH
FORK
ROLL
PINS
FIFTH GEAR
SHIFT FORK J9221-94
Fig. 33 Removing Fifth Gear Shift Fork Roll Pins
(2) Remove countershaft fifth speed clutch gear,
stop ring and bearing spacer (Fig. 34).
(3) Remove three struts and strut springs from
countershaft fifth gear hub and sleeve (Fig. 34).
(4) Remove mainshaft fifth gear nut and washer
as follows:
(a) Install nut wrench on fifth gear nut (Fig. 35).
Use Nut Wrench 6443 on standard duty models
and Wrench 6743 on heavy duty models.
(b) Note that wrench only fits one way on nut.
Be sure wrench is fully engaged in nut slots and is
not cocked.
(c) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel
drive models, install Socket Wrench 6442 on main-
shaft splines. Then install breaker bar in socket
wrench (Fig. 36). Wedge breaker bar handle
against workbench. Purpose of socket wrench and
breaker bar is to prevent mainshaft from turning
while nut is loosened.