Dodge ram truck 3500 1996 Service Manual page 1453

BR - NV4500 MANUAL TRANSMISSION 21 - 63
DISASSEMBLY AND ASSEMBLY
(Continued)
'SYNCHRO SLEEVE
FIFTH
GEAR
SHIFT SPRINGS
FORK
BEARING
SPACER
J9221-90
FIFTH
SYNCHRO
CLUTCH
GEAR
Fig, 34 Removing Countershaft Fifth Gear Synchro
Components
(d) Position small end of Nut Wrench 6443 at
approximately 10 o'clock position (Fig. 35).
(e) Strike small end of nut wrench with heavy
copper hammer to break nut loose. Nut is secured
by interference fit thread plus Loctite adhesive and
will require several firm blows to loosen i t (nut
torque is in 300 ft. lb. range).
(f) Once nut is loose, i t can be removed by hold­
ing nut wrench with breaker bar and rotating out­
put shaft with socket wrench and ratchet.
(g) Remove fifth gear nut and coned washer
from shaft (Fig. 37). Note position of washer for
assembly reference (coned side of washer faces
rear).
SPECIAL
TOOL
6443
OR 6743
STRIKE
TOOL
HERE
TO
LOOSEN
NUT
FIFTH
GEAR
NUT
J9421-207
Fig. 35 Installing Nut Wrench On Mainshaft Fifth
Gear
SPECIAL
TOOL
6443
OR 6743
FIFTH
GEAR
NUT
SPECIAL
TOOL
6441
OR
6442
RATCHET
WRENCH
BREAKER
BAR
J9421-208
Fig. 36 Removing Mainshaft Fifth Gear Nut From
Shaft Threads
FIFTH
GEAR
NUT
WASHER
'(CONED)
FIFTH
GEAR
NUT
J9221-93
Fig. 37 Mainshaft Fifth Gear Nut And Washer
Removal
(5) 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.
(6) Remove fifth gear shift fork and sleeve as
assembly (Fig. 38). Remove fork by tapping i t off rail
with plastic mallet. Leave sleeve engaged in fork
or note position of sleeve for assembly refer­
ence.
(7) Remove countershaft fifth gear and hub assem­
bly (Fig. 39).
(8) Remove countershaft fifth gear needle bearing
assemblies (Fig. 40).