Dodge Ram Truck 1500-2500-3500. Manual — part 1561

Front transmission leaks will be from the front input shaft retainer seal. Lubricant may drip from the clutch housing
after extended operation. If leak is severe, it may contaminate the clutch disc.

Lubricant level check can only be made when the vehicle is level and allowing the lubricant to settle for a minute
before checking. This will ensure an accurate check and avoid an under or overfill condition.

HARD SHIFTING

Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants. This will cause noise,
excessive wear, internal bind, and hard shifting. Substantial lubricant leaks can result in gear, shift rail, synchro, and
bearing damage. The first indications of component damage is usually hard shifting and noise.

Shift component damage, clutch adjustment, worn pressure plate or disc are also causes of increased shift effort. If
clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchronizer rings can cause
gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend
to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear-in.

TRANSMISSION NOISE

Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is
audible, but generally only at extreme speeds.

Severe, highly audible transmission noise is generally the initial indicator of a lubricant problem. Insufficient,
improper or contaminated lubricant will promote rapid wear of gears, synchronizer rings, shift rails, forks and bear-
ings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.

REMOVAL

1. With vehicle in neutral, position vehicle on hoist.

2. Disconnect battery negative cable.

3. Remove shift boot bezel screws and slide boot upward on shift lever extension.

4. Remove shift lever extension from the shift tower and lever assembly.

5. Remove skid plate, if equipped.

6. Remove drain plug and drain fluid.

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7. Mark propeller shaft/shafts and companion flange yoke/yokes for installation reference and remove propeller

shaft/shafts.

8. Disconnect harness from clips on transmission

housing.

9. Remove transfer case linkage 4x4 equipped.

10. Remove transfer case mounting nuts and remove

transfer case 4x4 equipped.

11. Remove slave cylinder (1) mounting nut (2) and

remove cylinder.

12. Remove starter motor (2), 5.7L structural dust

cover (3) bolts to clutch housing, dust shield (1)
bolt and suspension crossmember (4).

CAUTION: 5.7L engine only do not remove struc-
tural dust cover from enigne block. If cover is
removed

clutch

housing

and

cover

must

aligned with the engine.

13. Remove exhaust bracket (1) bolts and remove

bracket.

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MANUAL TRANSMISSION - G56 - SERVICE INFORMATION

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14. Support engine with adjustable jack stand and

wood block.

15. Support and secure transmission to a transmis-

sion jack with safety chains.

16. Remove transmission mount bolts (1).

17. Remove rear crossmember bolts (2) and remove

crossmember with transmission mount.

18. Remove

bolts

attaching

transmission

the

engine.

19. Move transmission rearward until input shaft is

clear of clutch disc and pressure plate. Then
lower jack and remove transmission from under
vehicle.

DISASSEMBLY

1. Set transmission on rear housing.

2. Remove shift tower bolts (1) and shift tower (2).

3. Pry off shift tower boot (1) with a screw driver (2).

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4. Through the shift tower opening (1) align shift rails

(2) and install tie strap to shift rails.

5. Remove 5-6 shift fork pivot pin (1) from both sides

of the case.

6. Remove reverse idler gear shaft pin (1) from the

rear housing (2).

DR/DH

MANUAL TRANSMISSION - G56 - SERVICE INFORMATION

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Dodge Ram Truck 1500-2500-3500. Manual — part 1561

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