Dodge 2001 Ram 1500 Owner's Manual page 1724

BR/BE
SHIFT MECHANISM (Continued)
Fig. 135 Shift Fork Pad Locations
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
EXPANSION PLUG
The expansion plugs at the rear of the shift rail
bores (Fig. 136) can be replaced if loose and/or leak-
ing.
Fig. 136 Expansion Plug Location
1 - EXPANSION PLUGS
(1) Drill 6 mm (1/4 in.) diameter hole in center of
each plug to be removed.
(2) Pry plug out of cover with tapered punch.
(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
INSTALLATION
EXPANSION PLUG
(1) Apply small bead of sealer to outer edge of
each new plug. Use Mopar silicone adhesive/sealer,
or equivalent.
(2) Position each new plug in bore and tap into
place with hammer and suitable size punch or socket.
MANUAL - NV4500
FIFTH-REVERSE SHIFT FORK PADS
(1) Align pad locating tab.
(2) Snap pads into place and verify locating tabs
are locked-in.
SHIFT COVER
(1) Clean mating surfaces of shift cover and gear
case with wax and grease remover.
(2) Apply Mopar Silicone Sealer, or equivalent, to
sealing surface of shift cover or gear case. Do not
over–apply sealer material. Excess can be squeezed
into gear case and could block lubricant feed holes in
time.
(3) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(4) Verify that the shift fork pads (Fig. 137) are
properly and securely positioned on the fifth-reverse
fork
Fig. 137 Fifth-Reverse Shift Fork Pads
1 - SHIFT FORK PADS
2 - FIFTH-REVERSE FORK
(5) Verify that 1-2 and 3-4 synchro sleeves are in
neutral position. Also verify that forks in shift cover
are in neutral position.
(6) Align and install shift cover. If cover will not
seat, it is either not aligned on gear case dowels, or
shift forks are not aligned with sleeves and shift lug.
(7) Apply Mopar Lock N' Seal, or equivalent, to
threads of shift cover bolts.
(8) Install and tighten shift cover bolts to 27-31
N·m (216-276 in. lbs.).
(9) Install backup lamp switch and gasket in cover.
Apply sealer to switch threads before installation and
tighten switch to 22-34 N·m (193-265 in. lbs.).
(10) Install vent assembly, if removed. Apply an
adhesive/sealer to vent tube to help secure it in cover.
(11) Install transmission.
21 - 89