Dodge Ram Truck 1500-2500-3500. Manual — part 1566

FRONT HOUSING

1. Remove countershaft bearing cup and mainshaft

bearing cup with Puller 9593 (1) installed in cup
(2).

2. Install Remover 8915 (1) on puller (2) and tighten

remover nut (3) to pull cups out of the housing.
Then remove end-play shims from bearing bores
and oil supply washer from mainshaft bearing bore.

3. Remove input shaft retainer (1) bolts (2) and

remove retainer.

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4. Remove input shaft seal (1) from retainer bore (2)

with a seal pick.

CLEANING

Clean gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use
acid or corrosive base solvents. Dry all parts except bearings with compressed air.

Clean shaft bearings with a mild solvent such as MOPAR

T

degreasing solvent, Gunk

T

or similar solvents. Do not

dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.

INSPECTION

NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out
with crocus cloth.

Bearings: Inspect for worn, chipped, cracked, flat-
spotted or brinnelled.

Gears: Inspect for worn, chipped or cracked teeth.
Inspect bearing surfaces for wear or flat-spotted.

Mainshaft:

Inspect

for

worn

splines,

snap

ring

grooves and threads.

Countershaft: Inspect all gears for worn, chipped or
cracked teeth (1). Inspect all bearings (2) and bearing
surfaces for ware or flat-spotted. The countershaft is
serviced as an assembly, except for bearings.

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Synchronizer

components:

Inspect

for

worn,

chipped or cracked teeth and burned or flaking off fric-
tion material. Synchronizer are serviced as an
assembly.

Input Shaft: Inspect shaft (1), bearing (2) surfaces for
wear or flat-spotted. Inspect fifth gear (3) for worn,
chipped or cracked teeth. Inspect splines (4) for wear
and chips.

Shift forks and Rails: Inspect shift forks (1) and
shoes for wear and distortion. Check fit of fork shoes
in synchronizer sleeve to ensure parts fit and work
smoothly. Inspect shift rails (2), for wear and distortion.
5-6 shift fork shoes (3) are serviced separately.

Housing/Tail housing: Inspect sealing and mating
surfaces are free of burrs and nicks. Inspect alignment
dowels are tight and in good condition. Inspect shift
rail bushings for wear.

Input Retainer: Inspect release bearing slide surface
(2) and sealing surface.

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ASSEMBLY

WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will
result in personal injury.

CAUTION: A bearing heater is used to assembly some components. Use only a bearing heater/hot plate and
follow manufactures instructions. Heat components to 100 - 177 Celsius (212° Min - 350° Max Fahrenheit).
Never use an open flame to heat components. Never leave components on heater for and extended amount
of time. If component is discolored after heating the component has been overheated and must not be
used. Failure to follow these instructions will result in component damage.

INPUT SHAFT

1. Heat input shaft bearing (1) on bearing heater (2).

2. Using welding gloves, install bearing (2) on input

shaft (1).

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