Dodge Ram Truck 1500-2500-3500. Manual — part 1540

TRANSMISSION GEAR CASE

1. Install rear output shaft bearing race into the trans-

mission gear case with Installer C-4308 and Han-
dle C-4171.

2. Install rear countershaft bearing race into the trans-

mission gear case with Installer 8153 and Handle
C-4171.

3. Install Fixture 8232 (1) to the transmission case

(2).

NOTE: Shift socket must be loose on the shift
shaft and is rotated a minimum of 90° from its nor-
mal position. This will ensure enough clearance to
install the transmission gear case.

4. Apply sealant to the clutch housing.

5. Attach an engine crane or equivalent to Fixture

8232 and install the transmission gear case onto
the clutch housing.

6. Install clutch housing bolts and tighten to 48 N·m

(35 ft.lbs.).

7. Install shift socket roll pin with a suitable 6 mm

(7/32 in.) punch and hammer.

MAINSHAFT AND COUNTERSHAFT ENDPLAY

1. With transmission in vertical position, use Socket

6993 to rotate the shafts and seat the bearings.

2. Measure mainshaft (3) endplay with Dial Indicator

Set C-3339 (1) and Extension Rod 8161 (2)
installed onto the rear of the transmission gear
case.

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3. Measure countershaft (3) end-play with Dial Indica-

tor Set C-3339 (2) and Extension Rod 8161 (1)
installed onto the rear of the transmission gear
case.

4. Rotate transmission into a horizontal position and

remove the input shaft retainer.

5. Install shims necessary to achieve an end-play of

0-0.10 mm (0-0.004 in.) for the mainshaft and
countershaft.

NOTE: Countershaft shims go between the bearing
race and spacer. Mainshaft shims go into the input
shaft retainer.

6. Install a new input shaft seal into the input shaft

retainer with Installer C-4965.

7. Install input shaft oil guide with C-3972-A and Han-

dle C-4171.

8. Apply sealer to the input shaft retainer and install

retainer onto the clutch housing. Install bolts and
tighten to 28 N·m (20 ft.lbs.).

REVERSE GEAR

1. Install reverse shift fork (2) and synchronizer (1) as

an assembly onto the reverse shift rail and output
shaft.

NOTE: Raised square shoulder and snap-ring on
the synchro face the case.

2. Install roll-pin securing the reverse shift fork to the

reverse shift rail with 6 mm (7/32 in.) punch and a
hammer.

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3. Install reverse gear bearing sleeve (1) onto the out-

put shaft with Installer 6446 if necessary.

4. Install reverse gear (1) , reverse gear synchronizer

cone (4), reverse gear outer blocker ring (3) and
reverse gear bearing (2).

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5. Install output shaft ball bearing (1) assembly and

reverse thrust washer (2) onto the output shaft.

NOTE: Raised shoulder on thrust washer faces
away from the reverse gear.

6. Install a new output shaft nut onto the output shaft.

7. With Wrench 8226 on the output shaft nut and

Socket 6993 or 6984 holding the output shaft,
tighten the nut to 339 N·m (250 ft.lbs.).

8. Stake nut into the slot in the output shaft with a 9

mm (5/16 in.) punch.

9. Press countershaft reverse gear into the sleeve

with a shop press.

10. Install reverse countershaft rear bearing onto the

countershaft reverse gear assembly with Installer C-4652 and Handle C-4171.

11. Install reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer onto the idler gear

shaft.

12. Install idler (1) and reverse countershaft gears (2)

together.

13. Install reverse idler thrust washer from the reverse

idler.

14. Install crossover cam rollers (2) and pin (1).

DR/DH

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