Dodge ram truck 3500 1996 Service Manual page 1485

BR
NV4500 MANUAL TRANSMISSION 21 - 95
CLEANING AN© INSPECTION
(Continued}
used to repair seriously damaged threaded holes i f
necessary.
Be sure all case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. This is
especially important as gaskets are not used in the
NV4500. Minor nicks and scratches on the sealing
surfaces can be dressed off with a fine tooth file or oil
stone.
Replace the gear case or housing/adapter If cracked
or broken. Do not attempt to repair this type of dam­
age by welding or brazing.
Check condition of the countershaft fifth gear com­
ponents (Fig. 179). This includes the shift lug and
rail located in the gear case and the rail bushings.
Inspect the gear and hub assembly. Minor burrs
can be cleaned up with an oil stone. However, the
gear and hub assembly should be replaced i f the
teeth or splines are excessively worn, or damaged.
The synchro sleeve should also be replaced If worn or
damaged in any way. Do not reuse synchro struts
that are worn, or springs that are collapsed or
severely distorted. Replace worn distorted synchro
parts to avoid shift problems after assembly and
Installation.
The shift fork should be inspected for evidence of
wear and distortion. Check fit of the sleeve In the
fork to be sure the two parts fit and work smoothly.
GEAR EXTENSION
Fig. 178 Gear Case And Extension/Adapter
Housings
Replace the fork If the roll pin holes are worn over­
size or damaged. Do not attempt to salvage a worn
fork. I t will cause shift problems later on. Replace
Fig. 179 Countershaft Fifth Gear Components