Dodge Ram Truck 1500-2500-3500. Manual — part 1541

EXTENSION/ADAPTER HOUSING

1. Install extension housing bushing with Installer

8156 and Handle C-4171, if necessary. The oil feed
hole must be at the 12 o’clock position when
installed.

2. On 4X2 vehicles, install extension housing seal

with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.

NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.

3. On 4X4 vehicles, install adapter housing seal with

Installer C-3860-A and Handle C-4171.

4. Install the crossover cam bushing into the exten-

sion/adapter housing with Installer 8239 and Han-
dle C-4171.

5. Clean the rear of the transmission case of all

sealer.

6. Install reverse countershaft gear bearing race onto

the reverse countershaft gear bearing.

7. Measure the distance (1) from the back of the bearing race to Gauge Bar 6311.

8. Measure thickness of the gauge bar and record the total of the two measurements.

9. Clean all the sealer from the extension/adapter

housing.

10. Place Gauge Bar 6311(1) across the housing

face. Measure the distance from the top of the bar
to the bottom of the reverse countershaft bearing
race bore.

11. Subtract thickness of the gauge bar from the mea-

surement and record the result.

12. The difference between the two measurements is

the end-play for the reverse countershaft gear
assembly.

13. Install

shims

to

achieve

0.15-0.25

mm

(0.006-0.010 in.) end-play for the reverse counter-
shaft gear assembly into the reverse countershaft
bearing race bore.

14. Use Installer to install the reverse countershaft

bearing race into the extension/adapter housing.

15. Install back-up lamp switch into the extension/

adapter housing and tighten to 28 N·m (20 ft.lbs.).

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16. Install crossover cam (1) into the extension/

adapter housing.

17. Install bolt (2) to hold the crossover cam to the

extension/adapter housing (3).

18. Install crossover detent plunger, spring and plug

(1) into the extension/adapter housing (2). Tighten
the plug to 47.5 N·m (35 ft.lbs.).

19. Apply sealer to the surface of the transmission

case.

20. Install extension/adapter housing onto the trans-

mission case.

21. Install bolts to hold the extension/adapter housing

onto the transmission gear case. Tighten bolts to
48 N·m (35 ft.lbs.).

22. Install shift rail blocker bolt and tighten bolt to 55

N·m (41 ft.lbs.).

23. Install primary shift rail detent plunger, spring and

plug into the transmission case. Tighten detent
plug to 47.5 N·m (35 ft.lbs.).

24. Install shift tower onto the transmission case and tighten bolts to 9 N·m (7 ft.lbs.).

INSTALLATION

NOTE: If installing a new transmission, use all
components supplied with the transmission. If a
new shift tower is supplied with the new transmis-
sion, do not re-use the original shift tower.

1. Apply a light coat of Mopar high temperature bear-

ing grease or equivalent to contact surfaces of fol-
lowing components:

•

release fork (1)

•

release fork ball stud (2)

•

release bearing slide (3)

•

input shaft splines (4)

•

release bearing bore (5)

2. Apply sealer to threads of bottom PTO cover bolt

and install bolt in case.

3. Mount transmission on jack and position transmission under vehicle.

4. Raise transmission until input shaft is centered in clutch disc hub.

5. Move transmission forward and start input shaft in clutch disc and pilot bushing/bearing.

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6. Work transmission forward until seated against engine block. Do not allow transmission to remain unsupported

after input shaft has entered clutch disc.

7. Install and tighten transmission-to-engine block bolts.

8. Install clutch slave cylinder.

9. Connect backup light switch wires.

10. Position transmission harness wires in clips on transmission.

11. Install transmission mount on transmission or rear crossmember.

12. Install rear crossmember.

13. Remove transmission jack and engine support fix-

ture.

14. Remove transmission fill plug (1) and fill with

required lubricant. Check lubricant level in transfer
case if equipped.

TWO WHEEL DRIVE

1. Install propeller shaft with reference marks aligned.

2. Install exhaust system components.

3. Remove support and lower vehicle.

4. Shift transmission into third gear.

5. Clean the mating surfaces of shift tower and isolator plate with suitable wax and grease remover.

6. Apply Mopar Gasket Maker or equivalent to sealing surface of the transmission case. Do not over apply sealant.

7. Install isolator plate onto the transmission case metal side down.

8. Install shift tower onto the isolator plate. No sealant is necessary between the shift tower and top of isolator

plate.

9. Verify shift tower, isolator plate and the shift socket are properly aligned.

10. Install bolts to hold the shift tower to the isolator plate and the transmission case. Tighten bolts to 10.2–11.25

N·m (7.5–8.3 ft. lbs.).

11. Install shift boot and bezel.

FOUR WHEEL DRIVE

1. Install and secure transfer case on the transmission jack.

2. Raise and align transfer case input gear with transmission mainshaft.

3. Move transfer case forward and seat it on adapter.

4. Install and tighten transfer case mounting nuts to 41-47 N·m (30-35 ft. lbs.) if case has 3/8 studs. If case has

5/16 studs tighten to 30-41 N·m (22-30 ft. lbs.).

5. Connect transfer case shift lever to range lever on transfer case.

6. Install propeller shafts with reference marks aligned.

7. Install transfer case skid plate, if equipped, and crossmember. Tighten attaching bolts/nuts to 41 N·m (30 ft. lbs.).

8. Install exhaust system components.

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9. Remove support and lower vehicle.

10. Shift transmission into third gear.

11. Clean the mating surfaces of shift tower, isolator plate and transmission case with suitable wax and grease

remover.

12. Apply Mopar Gasket Maker or equivalent to the sealing surface of the transmission case. Do not over apply

sealant.

13. Install isolator plate onto the transmission case, metal side down.

14. Install shift tower onto the isolator plate. No sealant is necessary between the shift tower and top of isolator

plate.

15. Verify that the shift tower, isolator plate and the shift tower bushings are properly aligned.

16. Install the bolts to hold the shift tower to the isolator plate and the transmission case. Tighten the shift tower

bolts to 10.2-11.25 N·m (7.5-8.3 ft. lbs.).

17. Install shift lever extension and tighten to 47 N·m (35 ft. lbs.).

18. Install shift lever boot and bezel.

SPECIFICATIONS - NV5600

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Plug, Crossover Cam and

Detent

48

35

-

Bolt, Input Retainer

28

20

-

Bolt, 5-6 Crossover

Bracket

28

20

-

Bolt, Clutch Housing

48

35

-

Bolt, Extension/Adapter

Housing

48

35

-

Bolt, Shift Tower

9

7

80

Shift Lever Extension

47

35

-

Switch, Back-up Lamp

28

20

-

Bolt, Shift Blocker

55

41

-

Bolt, PTO Cover

40

30

-

Pivot, Clutch Release

Lever

22

16

-

Plug, Fill

30

22

-

Nut, Output Shaft

339

250

-

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