Dodge ram truck 3500 1996 Service Manual page 1478

21 - 88 N¥4§80 MANUAL TRANSMISSION
BR
DISASSEMBLY AND ASSEMBLY (Continued)
(38) Install third gear bearings on mainshaft (Fig.
145). Upper bearing should be flush with mainshaft
hub. I f upper bearing is not flush w i t h hub,
either bearing spacer or snap r i n g was not
installed. Check and correct i f necessary.
THIRD
GEAR
BEARINGS
Fig. 145 Third Gear Bearing instaliation
(39) Install third gear over bearings and on main-
shaft (Fig. 146).
Fig. 146 Third Gear Instaliation
(40) Install synchro stop ring on third gear (Fig.
147). Be sure stop .ring is fully seated on gear taper.
SYNCHRO THIRD
Fig. 147 Third Gear Stop Ring Installation
(41) I f 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align and install synchro sleeve on hub (Fig.
148). F r o n t side of hub has a n a r r o w groove
machined i n i t .
(b) Insert all three synchro struts in slots
machined In sleeve and hub (Fig. 148).
(c) Install and seat synchro springs (Fig. 148).
Use flat blade or phillips screwdriver to compress
springs and seat them in struts and hub as shown.
STRUT (3) SPRING (3) 3-4 3-4
Fig. 148 Synchro Assembly (8-4)
(42) Remove mainshaft and geartrain from gear
case or from workbench.
(43) Start 3-4 synchro assembly on mainshaft. Tap
assembly onto shaft splines until hub is about 3 mm
(0.125 in.) away from third speed stop ring. Then
align stop ring with synchro sleeve and hub and seat
synchro assembly with Tool C-4040 (Fig. 149).
Fig. 149 Seating 3-4 Synchro Assembly On
Mainshaft
(44) Verify that 3-4 synchro hub is fully seated on
shaft. Approximately 3 mm (0.125 in.) of shaft spline
should be visible. I f hub is not seated, stop ring lugs
are misaligned. Rotate ring until lugs are fully
engaged in 3-4 hub slots.
(45) Install fourth speed stop ring in 3-4 synchro
sleeve (Fig. 150).
(46) Install fourth speed clutch gear in stop ring
(Fig. 151).
MAINSHAFT AND GEARTRAIN INSTALLATION
(1) Position gear case so case opening is facing up
(Fig. 152).