Dodge ram truck 3500 1996 Service Manual page 1482

21 - 92 NV4508 MANUAL TRANSMISSION
B l
DISASSEMBLY A N D ASSEMBLY (Continued)
COUNTERSHAFT FIFTH GEAR AMD SYNCHRO
INSTALLATION
(1) Install thrust washer pin in countershaft (Fig.
164).
COUNTERSHAFT
J9221-234
Fig. 164 Installing Fifth Gear Thrust Washer Pin
(2) Install thrust washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 165). Flat
side of washer faces rear and cone side to front as shown.
J9221-235
Fig. 165 Installing Fifth Gear Thrust Washer
(3) Lubricate and install fifth gear bearings on
countershaft (Fig. 166).
(4) Install bearing spacer on countershaft and seat
it against bearings (Fig. 166). Coat spacer with petro­
leum jelly to hold i t in place.
BEARING
SPACER
FIFTH
GEAR
BEARINGS
(5) Install synchro sleeve on hub of countershaft
fifth gear. Tapered side of sleeve faces front and flat
side faces rear (Fig. 167).
GEAR
SYNCHRO
SLEEVE
COUNTERSHAFT
FIFTH
GEAR
J9221-237
Fig. 167 Installing Synchro Sleeve On Countershaft
Fifth Gear Hub
(6) Install shift fork in synchro sleeve (Fig. 168).
SYNCHRO
SLEEVE
SHIFT
FORK
J9221-238
Fig. 168 Installing Fifth Gear Shift Fork In Synchro
Sleeve
(7) Install assembled fifth gear, synchro sleeve and
shift fork (Fig. 169). Align fork with shift lug rail and
align gear with bearings and countershaft. Start
components onto shaft and rail. Then tap gear and
fork into place with plastic or rawhide mallet.
(8) Align roll pin holes in shift fork with notches in
shift lug rail. Then install roll pins from top side of
fork (Fig. 169). Note that roll pins are one way fit
due to small shoulder at one end of each pin.
(9) Install synchro struts and springs in fifth gear
hub (Fig. 170). Install struts in hub slots first. Then
install springs by compressing them with screwdriver
and working springs into hub and struts.
(10) Assemble and install fifth synchro clutch gear
and stop ring in fifth gear hub (Fig. 171). Make sure
both parts are seated in fifth gear hub.
(11) Install clutch gear snap ring (Fig. 172).
J9221-236
Fig. 166 Countershaft Fifth Gear Bearing And
Spacer Installation