2001 Dodge RAM 3500 PICKUP - JustAnswer
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND A.1 of -012b-dd30-0019db6cff.2001 Dodge RAM 3500 PICKUPSubmodel: Engine Type: L6 Liters: 5.9Fuel Delivery: FI Fuel: DIESELSubarticlesMANUAL - NV4500 - DISASSEMBLYMANUAL - NV4500 - DISASSEMBLYMANUAL - NV4500 - ASSEMBLYDISASSEMBLYEXTENSION/ADAPTER HOUSING1.Raise and support vehicle.2.Remove rear propeller shaft.3.Support transmission with a transmission jack.4.Remove engine rear support. Refer to 9 Engine for procedures.5.Remove transfer case, if equipped.6.Remove bolts attaching extension/adapter housing to gear case Extension/Adapter Housing Bolts.Click to enlargeExtension/Adapter Housing Bolts1 - EXTENSION HOUSING2 - BOLTS7.Remove extension/adapter housing Extension/Adapter Housing. There is one alignment dowel in the gear case and one in the extension/adapterhousing.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeExtension/Adapter Housing1 - GEAR CASE2 - EXTENSION HOUSING8.Remove rubber spline seal from end of mainshaft Mainshaft Spline Seal. The seal is used to prevent lubricant loss during shipping and does not haveto be replaced if damaged.Click to enlargeMainshaft Spline Seal1 - MAINSHAFT2 - RUBBER SPLINE SEALFIFTH GEAR NUT2 of 781.Remove extension/adapter housing.2.Loosen fifth gear clamp nut clamping screw approximately 1 1/2 turns.3.Install nut Wrench 6743 on fifth gear nut Fifth Gear Nut.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeFifth Gear Nut1 - WRENCH 6443/67432 - FIFTH GEAR NUT3 - SCOCKET 6993/6984Important:Wrench only fits one way on nut. Be sure wrench is fully engaged in nut slots and is not cocked.1.Install splined Socket 6993 4X2 Socket 6984 4X4 to retain mainshaft while removing the fifth gear nut.2.Install breaker bar in socket wrench Fifth Gear NutClick to enlargeFifth Gear Nut1 - WRENCH 6443/67432 - FIFTH GEAR NUT3 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.3 - SCOCKET 6993/6984Important:Wedge breaker bar handle against workbench. Purpose of socket wrench and breaker bar is to prevent mainshaft from turning while nut is loosened.1.Remove fifth gear nut, then remove belleville washer from mainshaft.FIFTH GEAR1.Remove roll pins that secure countershaft fifth gear shift fork to shift rail with pin punch Fifth Gear Shift Fork Roll Pins. Roll pins are driven out frombottom of fork and not from top.Click to enlargeFifth Gear Shift Fork Roll Pins1 - FORK ROLL PINS2 - FIFTH GEAR SHIFT FORK2.Remove snap ring that secures fifth gear clutch hub and gear on countershaft Countershaft Fifth Gear Clutch Gear Snap Ring.Click to enlargeCountershaft Fifth Gear Clutch Gear Snap Ring1 - CLUTCH GEAR RING2 - FIFTH SYNCHRO CLUTCH GEAR4 of 783.Remove countershaft fifth gear clutch gear and stop ring.4.Remove fifth gear shift fork and gear assembly. Remove assembly by tapping fork off rail with plastic mallet.5.Remove fifth gear shift fork from sleeve.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.6.Remove sleeve, struts, and strut springs from countershaft fifth gear hub, if necessary.7.Remove countershaft fifth gear needle bearing assembly Countershaft Fifth Gear Needle Bearing.Click to enlargeCountershaft Fifth Gear Needle Bearing1 - FIFTH GEAR NEEDLE BEARING ASSEMBLY2 - COUNTERSHAFT8.Remove cone shaped rear bearing thrust washer from end of countershaft Countershaft Rear Bearing Thrust Washer. Note position of washer forassembly reference. Also note that washer bore has notch for locating pin.Click to enlargeCountershaft Rear Bearing Thrust Washer1 - THRUST WASHER(CONE SHAPED)2 - THRUST WASHER PIN5 of 789.Remove and retain thrust washer locating pin from countershaft.10.Remove mainshaft overdrive fifth gear with Puller Tool Set 6444.11.Position first Puller Jaw 6459 or 6820 on gear First Puller Jaw On Mainshaft Fifth (Overdrive) Gear.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeFirst Puller Jaw On Mainshaft Fifth (Overdrive) Gear1 - MAINSHAFT FIFTH GEAR2 - JAWS 6459 OR HD JAWS 68203 - MAINSHAFT12.Assemble Puller Flange 6444-1 and Puller Rods 6444-3 4X2 vehicles or 6444-4 4X4 vehicles Seating Puller Flange In First Puller.Click to enlargeSeating Puller Flange In First Puller1 - JAWS2 - PULLER FLANGE 6444-113.6 of 78Slide assembled puller flange and rods onto output shaft. Then seat flange in notch of puller jaw Seating Puller Flange In First Puller.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeSeating Puller Flange In First Puller1 - JAWS2 - PULLER FLANGE 6444-114.Position second puller jaw on gear and in notch of puller flange Retaining Collar Over Puller Jaws.Click to enlargeRetaining Collar Over Puller Jaws1 - JAWS2 - COLLAR 6444-815.7 of 78Slide Retaining Collar 6444-8 over puller jaws to hold them in place Retaining Collar Over Puller Jaws.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeRetaining Collar Over Puller Jaws1 - JAWS2 - COLLAR 6444-816.Install Puller and Bolt 6444 on puller rods. Then secure puller to rods with retaining nuts Fifth Gear From Mainshaft Splines.Click to enlargeFifth Gear From Mainshaft Splines1 - COLLAR 6444-82 - JAWS 6459 OR 68203 - BOLT 64444 - WRENCH5 - MAINSHAFT6 - PULLER FLANGE 6444-117.8 of 78Tighten puller bolt to remove gear from shaft splines Fifth Gear From Mainshaft Splines.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeFifth Gear From Mainshaft Splines1 - COLLAR 6444-82 - JAWS 6459 OR 68203 - BOLT 64444 - WRENCH5 - MAINSHAFT6 - PULLER FLANGE 6444-118.Remove bolts attaching mainshaft rear bearing plate to gear case and remove fifth gear plate end play shims and bearing cup Mainshaft Fifth GearBearing Plate, Bearing Shims, And Rear Bearing Cup.Click to enlargeMainshaft Fifth Gear Bearing Plate, Bearing Shims, And Rear Bearing Cup1 - MAINSHAFT REAR BEARING CUP2 - BEARING SHIMS3 - BEARING PLATE4 - FIFTH GEARFRONT RETAINER9 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND A.10 of 8f-012b-dd30-0019db6cff.Remove front retainer bolts Front Bearing Retainer. Discard retainer bolts. They should not be reused.Click to enlargeFront Bearing Retainer1 - DRIVE GEAR2 - FRONT BEARING RETAINER2.Remove retainer by lightly tapping it back and forth with plastic mallet. Then rock retainer back and forth by hand to work it out of gear case.Important:Retainer flange extends into transmission case and is a snug fit.1.Remove seal from front retainer Bearing Retainer Seal. Collapse one side of seal then pry it out with pry tool.Click to enlargeBearing Retainer Seal1 - SEAL2 - FRONT BEARING RETAINER2.To remove front retainer bearing cup, assemble Puller Flange 6444-1 and Puller Rods 6444-4 Puller Rods, Flange And Jaws.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargePuller Rods, Flange And Jaws1 - RODS 6444-42 - FLANGE 6444-13 - JAWS 6453-13.Insert Puller Jaws 6453-1 in puller flange Puller Rods, Flange And Jaws. Narrow lip of puller jaws will go under bearing cup.Click to enlargePuller Rods, Flange And Jaws1 - RODS 6444-42 - FLANGE 6444-13 - JAWS 6453-111 of 784.Install Disc C-4487-1 into bearing retainer on heavy duty transmissions for Insert 6453-2 to rest upon.5.Install assembled tools in front retainer Puller Tools In Front Retainer. Be sure puller jaws are seated under bearing cup.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargePuller Tools In Front Retainer1 - INSERT 6453-22 - FRONT RETAINER3 - JAWS 6453-16.Place Insert Tool 6453-2 in center of puller jaws Puller Tools In Front Retainer. Insert tool is used to hold puller jaws in place.Click to enlargePuller Tools In Front Retainer1 - INSERT 6453-22 - FRONT RETAINER3 - JAWS 6453-17.12 of 78Install Puller 6444 on puller rods Bearing Cup Puller. Then install retaining nuts on puller rods.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeBearing Cup Puller1 - WRENCH2 - INSERT 6453-23 - FRONT RETAINER4 - PULLER 64445 - WRENCH8.Tighten puller bolt to draw bearing cup out of retainer Bearing Cup Puller.Click to enlargeBearing Cup Puller1 - WRENCH13 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.2 - INSERT 6453-23 - FRONT RETAINER4 - PULLER 64445 - WRENCHDRIVE GEAR1.Remove drive gear Drive Gear.Click to enlargeDrive Gear1 - MAINSHAFT2 - DRIVE GEAR2.14 of 78Remove pilot bearing from drive gear Pilot Bearing.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargePilot Bearing1 - DRIVE GEAR2 - MAINSHAFT PILOT BEARING3.To remove tapered bearing from drive gear, assemble Puller Flange 6444-1 and Puller Rods 6444-6 Front Bearing Puller. Then position first PullerJaw 6447 on bearingClick to enlargeFront Bearing Puller15 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.1 - PULLER 64442 - RODS 6444-63 - JAWS 64474 - COLLAR 6444-85 - FLANGE 6444-16 - DRIVE GEAR16 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND 8f-012b-dd30-0019db6cff.Slide assembled puller flange and rod tools onto input shaft. Then seat flange in notch of puller jaw.5.Position second Puller Jaw 6447 on gear and in notch of puller flange.6.Slide Retaining Collar 6444-8 over puller jaws to hold them in place.7.Install Puller 6444 on puller rods then install retaining nuts.8.Tighten puller bolt to remove bearing cone from drive gear.MAINSHAFT AND GEARTRAIN1.Move 1-2 and 3-4 synchro sleeves into neutral.2.Remove drive gear thrust bearing from forward end of mainshaft Drive Gear Thrust Bearing.Click to enlargeDrive Gear Thrust Bearing1 - MAINSHAFT2 - DRIVE GEAR THRUST BEARING3.Remove fourth gear clutch gear and synchro stop ring from mainshaft Fourth Gear Clutch Gear Stop Ring.Click to enlargeFourth Gear Clutch Gear Stop Ring1 - FOURTH GEAR SYNCHRO STOP RING2 - FOURTH SPEED CLUTCH GEAR4.17 of 78Roll gear case onto left side Mainshaft And Geartrain.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeMainshaft And Geartrain1 - MAINSHAFT AND CASE5.To remove mainshaft assembly Mainshaft And Geartrainlift front end of mainshaft slightly.Click to enlargeMainshaft And Geartrain1 - MAINSHAFT AND CASEImportant:Handling mainshaft carfully because gears are lose on the mainshaft.1.Grasp mainshaft rear splines, then turn spline end of mainshaft counterclockwise to rotate shaft and geartrain out of case. Tilt mainshaft outward andremoved from case.REVERSE IDLER AND COUNTERSHAFT1.18 of 78Remove countershaft rear bearing plate Countershaft Rear Bearing Plate.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeCountershaft Rear Bearing Plate1 - REAR BEARING PLATE2 - COUNTERSHAFT2.Remove countershaft end play shim and rear bearing cup Countershaft End Play Shim And Rear Bearing Cup.Click to enlargeCountershaft End Play Shim And Rear Bearing Cup1 - COUNTERSHAFT REAR BEARING CUP2 - END PLAY SHIM3.19 of 78Remove reverse idler shaft Reverse Idler Shaft.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeReverse Idler Shaft1 - REVERSE IDLER SHAFT4.Rotate countershaft outward and push reverse idler gear away from countershaft and toward front of case Idler Gear Moved Away FromCountershaft.Click to enlargeIdler Gear Moved Away From Countershaft1 - REVERSE IDLER GEAR2 - COUNTERSHAFT5.20 of 78Remove idler gear Reverse Idler Gear.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeReverse Idler Gear1 - REVERSE IDLER GEAR2 - DRIVE GEAR BORE6.Keep reverse idler gear bearings and spacer together for cleaning and inspection Idler Gear Components. Insert idler shaft through gear andbearings to keep them in place.Click to enlargeIdler Gear Components1 - BEARINGS2 - REVERSE IDLER GEAR7.Remove idler gear thrust washers from gear case. Install washers on idler shaft to keep them together for cleaning and inspection.8.To remove countershaft rear bearing ,assemble Puller Flange 6444-1 and Puller Rods 6444-4 Countershaft Rear Bearing.Click to enlargeCountershaft Rear Bearing21 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.1 - COLLAR 6444-82 - JAWS 64493 - PULLER 64444 - WRENCHImportant:Shaft cannot be removed from case until rear bearing has been removed.1.Position first Puller Jaw 6449 on bearing cone2.Seat puller flange in notch of puller jaw just installed on bearing cone3.Install second Puller Jaw 6449 on bearing and in notch of puller flange4.Slide Retaining Collar 6444-8 over puller jaws to hold them in placeImportant:Retaining collar has small lip on one end and only fits one way over jaws.1.Install Puller 6444 on puller rods, then secure puller to rods with retaining nuts2.Tighten puller bolt to remove bearing from shaft. If bearing is exceptionally tight, tap end of puller bolt with copper mallet to help loosen bearing.3.Remove bearing puller tools then rotate countershaft out of gear case Countershaft And Case.Click to enlargeCountershaft And Case1 - COUNTERSHAFT4.ToRemove countershaft front bearing, assemble Puller Flange 6444-1 and Puller Bolts 6444-4 Countershaft Front Bearing.Click to enlarge22 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Countershaft Front Bearing1 - JAWS 64512 - COLLAR 6444-83 - PULLER 64444 - FLANGE 6444-15.Position first Puller Jaw 6451 on bearing.6.Seat puller flange in notch of puller jaw.7.Install second Puller Jaw 6451 on bearing and in notch of puller flange.8.Slide Retaining Collar 6444-8 over puller jaws to hold them in placeImportant:Retaining collar has small lip on one end and only fits one way over jaws.1.Install puller bridge and bolt assembly 6444 on puller bolts and install retaining nuts2.Tighten puller bolt to remove bearing from shaft. If bearing is exceptionally tight, tap end of puller bolt with mallet to help loosen bearing.3.Remove bearing puller tools.GEAR CASE1.Remove countershaft front bearing cap with mallet or hammer Countershaft Front Bearing Cap.Click to enlargeCountershaft Front Bearing Cap1 - HAMMER2 - BEARING CAP2.Remove countershaft front bearing cup with Remover 6454 and Handle C-4171 Countershaft Front Bearing Cup.Click to enlargeCountershaft Front Bearing Cup23 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.1 - REMOVER 64542 - HANDLE C-41713.Remove roll pin that secures shift lug on shift rail in case Shift Lug Roll Pin. A small pin punch can be modified by putting a slight bend in it to drivepin completely out of shift rail Shift Lug Roll Pin.Click to enlargeShift Lug Roll Pin1 - PUNCH2 - 30 BEND3 - PIN PUNCH MODIFICATION4 - SHIFT LUG5 - SHIFT RAIL24 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeShift Lug Roll Pin1 - PUNCH2 - 30 BEND3 - PIN PUNCH MODIFICATION4 - SHIFT LUG5 - SHIFT RAIL4.Remove shift lug rail.MAINSHAFTImportant:Not all of the mainshaft gear and synchro components are a one-way fit. Some gear and synchro components can be installed backwards. Paint or scriber gear andsynchro components for installation reference. Then stack geartrain parts in order of removal to avoid incorrect assembly.1.Remove drive gear thrust bearing from end of mainshaft, if not previously removed.2.Remove 3-4 synchro hub, third gear stop ring and third gear as an assembly Third Gear, Stop Ring, And 3-4 Hub.Click to enlargeThird Gear, Stop Ring, And 3-4 Hub1 - THIRD GEAR2 - THIRD GEAR STOP RING3 - 3-4 SYNCHRO HUB3.25 of 78Remove third gear bearing from mainshaft Third Gear Bearing.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeThird Gear Bearing1 - THIRD GEAR NEEDLE BEARING4.Remove third gear bearing spacer Snap Ring And Third Gear Bearing Spacer.Click to enlargeSnap Ring And Third Gear Bearing Spacer1 - SECOND GEAR THRUST WASHER2 - THRUST WASHER SNAP RING3 - THIRD GEAR BEARING SPACER5.26 of 78Remove second gear thrust washer snap ring from mainshaft Snap Ring And Third Gear Bearing Spacer.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeSnap Ring And Third Gear Bearing Spacer1 - SECOND GEAR THRUST WASHER2 - THRUST WASHER SNAP RING3 - THIRD GEAR BEARING SPACER6.Remove second gear thrust washer Second Gear Thrust Washer. Note that washer is notched for locating pin.Click to enlargeSecond Gear Thrust Washer1 - SECOND GEAR2 - THRUST WASHER3 - SECOND GEAR BEARING7.27 of 78Remove thrust washer locating pin Thrust Washer Locating Pin. Use needle nose pliers to remove pin.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND A.28 of -012b-dd30-0019db6cff.Click to enlargeThrust Washer Locating Pin1 - THRUST WASHER LOCATING PIN8.Remove second gear Second Gear.Click to enlargeSecond Gear1 - SECOND GEAR9.Remove second gear bearing Second Gear Bearing.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeSecond Gear Bearing1 - SECOND GEAR NEEDLE BEARING10.Remove second gear clutch cone snap ring Second Gear Clutch Cone Snap Ring. Snap ring is seated in mainshaft synchro hub groove.Click to enlargeSecond Gear Clutch Cone Snap Ring1 - 1-2 SLEEVE2 - SNAP RING3 - SECOND GEAR CLUTCH CONE11.29 of 78Remove second gear clutch cone, synchro clutch ring and synchro stop ring Second Gear Clutch Cone And Ring.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeSecond Gear Clutch Cone And Ring1 - 1-2 SLEEVE AND HUB2 - SYNCHRO STOP RING3 - CLUTCH RING4 - SECOND GEAR CLUTCH CONE12.Remove 1-2 synchro hub snap ring 1-2 Sleeve And Hub Snap Ring.Click to enlarge1-2 Sleeve And Hub Snap Ring1 - 1-2 HUB SNAP RING2 - 1-2 SLEEVE AND HUB13.30 of 78Remove 1-2 synchro sleeve, hub, struts and springs as an assembly 1-2 Synchro Sleeve And Hub. Note that tapered side of sleeve also goes towardfront. Do not disassemble synchro components unless worn or damaged.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlarge1-2 Synchro Sleeve And Hub1 - 1-2 SLEEVE AND HUB14.Remove first gear synchro stop ring and clutch ring First Gear Stop And Clutch Ring.Click to enlargeFirst Gear Stop And Clutch Ring1 - FIRST GEAR CLUTCH RING2 - FIRST GEAR STOP RING15.Remove first gear clutch cone front snap ring from mainshaft hub First Gear Clutch Gear Front Snap Ring.Click to enlargeFirst Gear Clutch Gear Front Snap Ring31 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.1 - FIRST SPEED CLUTCH GEAR2 - CLUTCH GEAR SNAP RING (FRONT)16.Remove first gear clutch cone First Gear Clutch Gear.Click to enlargeFirst Gear Clutch Gear1 - CLUTCH GEAR SNAP RING (REAR)2 - FIRST SPEED CLUTCH GEAR17.Remove first gear clutch gear rear snap ring from mainshaft hub First Gear Clutch Gear. Do not remove this snap ring unless mainshaft is to bereplaced.Click to enlargeFirst Gear Clutch Gear1 - CLUTCH GEAR SNAP RING (REAR)2 - FIRST SPEED CLUTCH GEAR18.32 of 78To remove mainshaft rear bearing, assemble Puller Flange 6444-1 and Puller Rods 6444-3 for 4X2 or 6444-4 for 4X4 Mainshaft Rear Bearing Puller.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeMainshaft Rear Bearing Puller1 - REAR BEARING2 - FLANGE 6444-13 - JAW 64454 - COLLAR 6444-85 - MAINSHAFT6 - PULLER 64447 - RODS 6443-3 OR 6444-48 - JAW 644519.Position the first Puller Jaw 6445 on the bearing cone.20.Seat Puller Flange 6444-1 in notch of first puller jaw.21.Install the second Puller Jaw 6445 on the bearing cone and puller flange.22.Install Puller 6444 on the puller rods and secure with nuts.23.Hold hex portion of Puller 6444 a wrench Mainshaft Rear Bearingand tighten screw.Click to enlargeMainshaft Rear Bearing1 - JAWS 644533 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.2 - COLLAR 6444-83 - FLANGE 6444-14 - MAINSHAFT5 - PULLER 64446 - TIGHTENING WRENCH7 - HOLDING WRENCH8 - RODS 6444-3 OR 6444-424.Remove bearing puller tools and rear mainshaft bearing from output shaft.25.Remove reverse gear thrust washer Reverse Gear Thrust Washer.Click to enlargeReverse Gear Thrust Washer1 - REVERSE GEAR2 - THRUST WASHER26.Remove reverse gear and synchro components as assembly Reverse Gear, Bearing, And Stop Ring. Do not disassemble synchro componentsunless they are damaged. If synchro sleeve or struts require service, mark position of sleeve on hub before removal. Correct sleeve position isimportant as sleeve can be installed backwards causing shift problems.Click to enlargeReverse Gear, Bearing, And Stop Ring1 - FIRST GEAR2 - REVERSE GEAR ASSEMBLY34 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.3 - BEARING ASSEMBLY4 - STOP RING27.Remove reverse gear bearing assembly from mainshaft Reverse Gear, Bearing, And Stop Ring.Click to enlargeReverse Gear, Bearing, And Stop Ring1 - FIRST GEAR2 - REVERSE GEAR ASSEMBLY3 - BEARING ASSEMBLY4 - STOP RING28.Remove reverse gear bearing spacer from mainshaft Reverse Gear Bearing Spacer And First Gear Snap Ring.Click to enlargeReverse Gear Bearing Spacer And First Gear Snap Ring1 - CLUTCH GEAR SNAP RING2 - REVERSE GEAR BEARING SPACER29.35 of 78Remove reverse clutch gear snap ring Reverse Gear Bearing Spacer And First Gear Snap Ring. Tension of this snap ring is considerable. Heavy dutysnap ring pliers will be required to spread the ring far enough to remove it.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND A.36 of -012b-dd30-0019db6cff.Click to enlargeReverse Gear Bearing Spacer And First Gear Snap Ring1 - CLUTCH GEAR SNAP RING2 - REVERSE GEAR BEARING SPACER30.Remove reverse clutch gear Reverse Clutch Gear.Click to enlargeReverse Clutch Gear1 - REVERSE CLUTCH GEAR31.Remove first gear from bearing and mainshaft First Gear.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeFirst Gear1 - FIRST GEAR32.Remove first gear bearing from mainshaft First Gear Bearing.Click to enlargeFirst Gear Bearing1 - MAINSHAFT2 - FIRST GEAR BEARINGASSEMBLYImportant:Gaskets are not used in the NV4500 transmission. Use Mopar Silicone Sealer or equivalent on all gear case and extension housing sealing surfaces.COUNTERSHAFT AND REVERSE IDLER GEAR37 of 781.Install countershaft front bearing cup in case with Handle C-4171 and Installer 6061-1.2.Install front bearing on countershaft with Installer C-4340 Countershaft Front Bearing.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeCountershaft Front Bearing1 - FRONT BEARING2 - INSTALLER C-43403 - COUNTERSHAFT3.Lubricate countershaft front bearing cup and cone with petroleum jelly.4.Position gear case on end with rear of case facing up Countershaft In Gear Case.Click to enlargeCountershaft In Gear Case1 - GEAR CASE2 - COUNTERSHAFT5.38 of 78Install countershaft in gear case Countershaft In Gear Case.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND A.39 of -012b-dd30-0019db6cff.Click to enlargeCountershaft In Gear Case1 - GEAR CASE2 - COUNTERSHAFTImportant:Do not install rear countershaft bearing on countershaft at this time.1.Lubricate reverse idler gear bearings with petroleum jelly and install first bearing and second bearing Idler Gear Front Thrust Washer.Click to enlargeIdler Gear Front Thrust Washer1 - POSITION IDLER GEAR FRONT THRUST WASHER ON BOSS2.Install idler gear front thrust washer on boss in gear case Idler Gear Front Thrust Washer. Coat thrust washer with liberal quantity of petroleum jelly tohold it in place.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeIdler Gear Front Thrust Washer1 - POSITION IDLER GEAR FRONT THRUST WASHER ON BOSS3.Install reverse idler gear in case Idler Gear.Click to enlargeIdler Gear1 - REAR THRUST WASHER2 - REVERSE IDLER GEAR3 - FRONT THRUST WASHER4.Install idler gear rear thrust washer between idler gear and case boss Idler Gear.Click to enlargeIdler Gear40 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.1 - REAR THRUST WASHER2 - REVERSE IDLER GEAR3 - FRONT THRUST WASHER41 of 789/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.5.Align idler gear bearings and thrust washers with a drift.6.Install reverse idler shaft with notched end of shaft facing countershaft Reverse Idler Shaft.Click to enlargeReverse Idler Shaft1 - COUNTERSHAFT2 - SHAFT NOTCH MUST FACE COUNTERSHAFT3 - REVERSE IDLER SHAFT7.Lift countershaft upward and position wood block between front of shaft and case Supporting Countershaft With Wood Block.Click to enlargeSupporting Countershaft With Wood Block1 - COUNTERSHAFT2 - WOOD BLOCK8.42 of 78Install rear bearing cone on countershaft with Installer C-4040 Countershaft Rear Bearing.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeCountershaft Rear Bearing1 - INSTALLER C-40402 - REAR BEARING3 - COUNTERSHAFT9.Remove wood block from under countershaft and lower countershaft front bearing into front bearing cup.10.Lubricate countershaft rear bearing cup and cone with petroleum jelly.11.Install countershaft rear bearing cup in gear case and over rear bearing Countershaft Rear Bearing Cup. Tap cup into place with plastic mallet ifnecessary.Click to enlargeCountershaft Rear Bearing Cup1 - COUNTERSHAFT REAR BEARING CUP12.43 of 78Install countershaft rear bearing plate Countershaft Rear Bearing Plate.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeCountershaft Rear Bearing Plate1 - COUNTERSHAFT2 - REAR BEARING PLATE3 - IDLER SHAFTImportant:Verify plate is seated in notch in reverse idler shaft before tightening bearing plate bolts.1.Apply Mopar silicone adhesive/sealer to flange and lip of new cap. Install newfront bearing cap in gear case Countershaft Front Bearing CapwithHandle C-4171 and Installer C-3972-A.Click to enlargeCountershaft Front Bearing Cap1 - FRONT BEARING CAP (SEAT WITH WOOD BLOCK)COUNTERSHAFT END PLAY44 of 781.Rotate countershaft 4-5 times to seat bearings.2.Mount dial indicator on case. Then position indicator plunger on end of countershaft and zero dial indicator Measuring Countershaft End Play.9/14/2012 7:00 PM
MANUAL - NV4500 - MANUALNV4500 - DISASSEMBLY AND -012b-dd30-0019db6cff.Click to enlargeMeasuring Countershaft End Play1 - DIAL INDICATOR2 - COUNTER SHAFT3 - INDICATOR MOUNTING ARM AND BASE3.Raise countershaft with screwdriver and note end play reading on dial indicator. End play should be 0.051 - 0.15 mm (0.002 - 0.006 in.).4.Remove countershaft rear bearing plate.5.Install a end pl
Fifth Gear Nut 1 - WRENCH 6443/6743 2 - FIFTH GEAR NUT 3 - SCOCKET 6993/6984 Important: Wrench only fits one way on nut. Be sure wrench is fully engaged in nut slots and is not cocked. 1. Install splined Socket 6993 4X2 Socket 6984 4X4 to retain mainshaft while removing the fifth gear nut. Install breaker bar in socket wrench Fifth Gear Nut .
P40. These vehicles must also complete Safety Recall R25. 2004-2008 (DR) Dodge RAM 1500/2500/3500 Pickup 2005-2009 (DH) Dodge RAM 1500/2500/3500 Pickup 2006-2009 (D1) Dodge RAM 3500 Pickup 2007-2009 (DC) Dodge RAM 3500 Cab Chassis 2008-2010 (DM) Dodge RAM 4500/5500 Cab Chassis 2004-2008 (HB) Dodge Durango 2007-2008 (HG) Chrysler Aspen
Recall/Action Population Safety Recall R25 - Driver Airbag Inflator 2004 - 2008 (DR) Dodge Ram 1500/2500/3500 2005 - 2009 (DH) Dodge Ram 2500 2006 - 2009 (D1) Dodge Ram 3500 2007 - 2009 (DC) Dodge Ram 3500 Cab Chassis 2008 - 2010 (DM) Dodge Ram 4500/5500 Cab Chassis 2004 - 2008 (HB) Dodge Durango 2007 - 2008 (HG) Chrysler Aspen
The Dodge Ram Wagon Van fuel tank is rated at 3600 psig. Figure 1. CNG- and HCNG-fueled Dodge Ram Wagon Van. Table 2. Dodge Ram Wagon Van factory specifications. Engine 5.2 L V8 Factory HP 150 Curb weight 5529 lb GVWR 7700 lb Emissions Summary The Dodge Ram Wagon Van was tested at ATL, operating on both CNG and on a blend of 15% hydrogen-85% CNG.
2005 - 2005 (ND) Dodge Dakota CUSTOMER VERBIAGE "FA has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 through 2005 model year Dodge Ram 1500/2500/3500 Pickup, 2004 through 2005 model year Dodge Durango, 2005 model year Chrysler 300/Dodge Charger/Dodge Magnum, and 2005 model year Dodge Dakota vehicles."
Dealer Service Instructions for: Safety Recall P80 / NHTSA 14V-795 Clutch Interlock Switch 2006 – 2007 (DR) Dodge RAM Truck (1500 series) (DH) Dodge RAM Truck (2500/3500 series) (D1) Dodge RAM Truck (3500 series) (ND) Dodge Dakota NOTE: This recall applies only to the above vehicles equipped with a manual
Recall/Action Population Safety Recall R25 - Driver Airbag Inflator 2004 - 2008 (DR) Dodge Ram 1500/2500/3500 2005 - 2009 (DH) Dodge Ram 2500 2006 - 2009 (D1) Dodge Ram 3500 . Dodge Charger and occurred in southern Florida, where there is high absolute humidity."
Recall/Action Population Safety Recall R25 - Driver Airbag Inflator 2004 - 2008 (DR) Dodge Ram 1500/2500/3500 2005 - 2009 (DH) Dodge Ram 2500 2006 - 2009 (D1) Dodge Ram 3500 . Dodge Charger and occurred in southern Florida, where there is high absolute humidity."
Oct 14, 2006 · 35 2001 dodge pickup, 3/4t, 4dr, quad cab, diesel, 4x4 116,799 mi. 36 1994 ford pickup 130,277 mi. 37 1997 ford taurus 129,844 mi. 38 2002 dodge pickup, 3/4t, 4dr, ext cab, 4x4 120,064 mi. 39 1993 chevrolet cavalier 121,932 mi. 40 1995 dodge maxivan 98,606 mi. 41 1995 pontiac grand am 126,414 mi. 42 1987 gmc pickup, 3/4t 136,239 mi.
