Dodge Ram Truck 1500-2500-3500. Manual — part 1520
3. Remove tapered bearing from drive gear (6) with
Puller Flange 6444-1 (5) and Puller Rods 6444-6
(2).
4. Position first Jaw 6447 (3) on bearing. Slide
assembled puller flange and rod tools onto input
shaft. Then seat flange in notch of puller jaw.
5. Position second Jaw 6447 on gear and in notch of
puller flange. Slide Collar 6444-8 (4) over puller
jaws to hold them in place.
6. Install Puller 6444 (1) on puller rods then install
retaining nuts. Tighten puller bolt to remove bearing
cone from drive gear.
MAINSHAFT AND GEARTRAIN
1. Move 1-2 and 3-4 synchro sleeves into neutral.
2. Remove drive gear thrust bearing (1) from forward
end of mainshaft (1).
3. Remove fourth gear clutch gear (2) and synchro
stop ring (1) from mainshaft.
4. Roll gear case onto left side.
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NOTE: Handling mainshaft carefully because gears
are lose on the mainshaft.
5. Remove mainshaft assembly (1) by lifting front end
of mainshaft slightly. Then grasp mainshaft rear
splines and turn spline end of mainshaft counter-
clockwise to rotate shaft and geartrain out of case.
Tilt mainshaft outward and removed from case.
REVERSE IDLER AND COUNTERSHAFT
1. Remove countershaft (2) rear bearing plate (1).
2. Remove countershaft end play shim (2) and rear
bearing cup (1).
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MANUAL TRANSMISSION - NV4500 - SERVICE INFORMATION
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3. Remove reverse idler shaft (1).
4. Rotate countershaft (2) outward and push reverse
idler gear (1) away from countershaft and toward
front of case.
5. Remove idler gear (1).
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6. Keep reverse idler gear (2) bearings (1) and spacer
together. Insert idler shaft through gear and bear-
ings to keep them in place.
7. Remove idler gear thrust washers from gear case.
Install washers on idler shaft to keep them together
for cleaning and inspection.
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.
8. Remove countershaft rear bearing with Puller
Flange 6444-1 and Puller Rods 6444-4.
9. Position first Jaw 6449 (2) on bearing cone and
seat puller flange in notch of puller.
10. Install second Jaw 6449 on bearing and in notch
of puller flange. Slide Collar 6444-8 (1) over puller
jaws.
11. Install Puller 6444 (3) on puller rods, then secure
puller to rods with retaining nuts. Tighten puller
bolt to remove bearing from shaft. Tap end of
puller bolt with copper mallet to help loosen bear-
ing if necessary.
12. Remove bearing puller tools then rotate counter-
shaft (1) out of case.
DR/DH
MANUAL TRANSMISSION - NV4500 - SERVICE INFORMATION
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