Dodge Ram Truck 1500-2500-3500. Manual — part 1539

3. Install input shaft bearing oil guide with Installer

MD998805.

4. Place the output shaft pocket bearing race in the

input shaft.

5. Install output shaft bearing race into input shaft (2)

with Installer C-4628 (3) and Handle C-4171(1).

CLUTCH HOUSING

1. Install input shaft bearing race so that the bearing

race protrudes 0.3 in. (1) above the front surface of
the

clutch

housing.

Install

bearing

race

with

Remover/Installer 8237 and Handle C-4171.

2. Install countershaft front bearing race into the

clutch housing so that the bearing race protrudes
0.4 in. (2) above the front surface of the clutch
housing. Install bearing race with Remover 6061-1
and Handle C-4171.

3. Install countershaft oil guide and spacer into the

countershaft front bearing bore in the clutch hous-
ing.

4. Clean old sealer from input shaft retainer and

clutch housing. DO NOT apply new sealer at this
time. New sealer will be applied after all the pre-
load measurements are made and end-play shims
are installed.

NOTE: Do not replace the input shaft seal at this
time. A new seal will be installed after all the pre-
load measurements are made and endplay shims
are installed.

5. Install input shaft retainer onto the clutch housing and install bolts to hold the input shaft retainer.

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GEARTRAIN

1. Install input shaft (2) into Support Stand 8246 (3).

2. Install fifth gear friction cone onto the input shaft.

3. Install fifth gear blocker ring onto the fifth gear fric-

tion cone.

4. Install output shaft into the input shaft (1).

5. Install countershaft (1) into the Support Stand 8246

(3) and verify that all gears are meshed with their
mates on the output shaft (2).

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6. Install Fixture 8232 (1) to the output shaft and

countershaft.

7. Install Holding Tool 8242 onto the 5-6 synchro and

tighten the screw to hold the 5-6 synchro together
during the remainder of the installation procedure.

8. Attach a engine crane or equivalent to Fixture 8232

(1) and move the geartrain from the Support Stand
8246 (2) to the clutch housing.

9. Install shift forks and rails (1) onto the geartrain.

NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.

10. Install geartrain and shift rails into the clutch

housing. Lower the geartrain and rails into the
housing slowly while guiding input shaft through
input shaft seal. Avoid any binds on the shift rails,
forks and synchros as the rails enter their bush-
ings.

CAUTION: Do not damage input shaft seal with the
input shaft splines.

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11. With the geartrain approximately 1/4 in. from the

clutch housing, remove Holding Tool 8242 (1) from
the 5-6 synchro (2).

12. Install 5-6 crossover bracket and arm to the shift

rails and the clutch housing.

13. Lower geartrain the remainder of the way into the

clutch housing.

14. Install the 5-6 crossover bracket (1) bolts and

tighten to 28 N·m (20 ft. lbs.).

15. Remove engine crane and Fixture 8232 from the

output shaft and the countershaft.

DR/DH

MANUAL TRANSMISSION - NV5600 - SERVICE INFORMATION

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