Dodge Ram Truck 1500-2500-3500. Manual — part 1524

16. Install countershaft rear bearing cup (1) in gear

case and over rear bearing. Tap cup into place
with plastic mallet if necessary.

17. Install countershaft (1) rear bearing plate (2). Ver-

ify plate is seated in notch in reverse idler shaft
before tightening bearing plate bolts.

18. Apply Mopar silicone adhesive/sealer or equiva-

lent to flange and lip of new front bearing cap (1).
Install cap in gear case with Handle C-4171 and
Installer C-3972-A.

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COUNTERSHAFT END PLAY

1. Rotate countershaft 4-5 times to seat bearings.

2. Mount dial indicator (1) on case. Then position indi-

cator plunger on end of countershaft (2) and zero
dial indicator.

3. Raise countershaft with screwdriver and note end

play reading on dial indicator. End play should be
0.051 - 0.15 mm (0.002 - 0.006 in.).

4. Remove countershaft rear bearing plate.

5. Install a end play shim (2) that will provide mini-

mum countershaft end play. Position shim on rear
bearing cup (1).

6. Install countershaft rear bearing plate. Verify plate

is seated in reverse idler shaft notch and end play
shims are still in position before installing bolts.

7. Apply 1-2 drops Mopar Loc N’ Seal or equivalent to

threads of rear bearing plate bolts. Then install and
tighten bearing plate bolts to 23 N·m (200 in. lbs.).

SHIFT LUG AND RAIL

1. Lubricate shift lug and rail with Castrol

T

Syntorq or

equivalent.

2. Insert shift lug rail (2) part way into case.

3. Install shift lug (4) on rail.

4. Position shift rail so roll pin notches (1) are toward

outside of case.

5. Install roll pin (3) that secures lug to rail.

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MAINSHAFT AND GEARTRAIN

CAUTION: The reverse, 1-2 and 3-4 synchro com-
ponents can be assembled and installed incor-
rectly. Follow assembly procedures for component
identification and location.

Lubricate mainshaft bearing surfaces and all bearing
assemblies with Castrol

T

Syntorq or with petroleum

jelly.

1. Install first gear clutch gear snap ring (1) in rear

most groove of mainshaft hub (3).

2. Install first gear clutch cone (2) on mainshaft 1-2

synchro hub (1) with recessed side of cone facing
front. Verify cone is seated against snap ring on
hub.

3. Install snap ring (3) on mainshaft 1-2 synchro hub

(2) to secure clutch cone (1). Verify snap ring is
seated in hub groove and against clutch cone.

4. Support mainshaft in upright position to install

remaining gears, snap rings and synchro compo-
nents. Shaft can be supported in gear case or hole
can be cut in workbench to support shaft.

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If 1-2 synchro hub (2) and sleeve (1) were disassem-
bled for service, reassemble hub, sleeve, struts and
springs as follows:

5. Align and install sleeve on hub. Rotate sleeve until

it slides onto hub. Sleeve only fits one way and will
easily slide onto hub when long slot in sleeve,
aligns with long shoulder on hub.

6. Place wood blocks (1) under hub (2) that will raise

hub about 3.5 cm (1.375 in.) above surface of
workbench. Then allow sleeve to drop down on
hub.

7. Install springs and struts in hub (4). Use lots of

petroleum jelly to hold them in place. Then com-
press struts with your fingers and move sleeve (3)
upward until struts are started in sleeve. Verify that
struts are engaged in sleeve before proceeding.

8. Turn synchro assembly upright. Then move sleeve

into neutral position on hub and work struts into
sleeve at same time. Be sure struts are seated and
springs are not displaced during assembly.

9. Install first gear stop ring in 1-2 synchro hub and

sleeve. Verify stop ring is seated and engaged in
hub and sleeve.

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