Dodge Ram Truck 1500-2500-3500. Manual — part 1528
9. Install clutch gear snap ring (1).
10. Align roll pin holes in shift fork with notches in
shift lug rail. Then install roll pins from top side of
fork.
FIFTH GEAR NUT
1. Install belleville washer onto the mainshaft.
2. Install fifth gear nut over the mainshaft.
3. Tighten the clamp bolt until the gap in the clamp
nut assembly is closed.
4. Back the clamp bolt off one full turn.
5. Place 10-15 drops of Loctite 272 onto the main-
shaft threads where the fifth gear (1) nut (2) will be
engaged.
6. Install fifth gear nut on mainshaft.
7. Hold mainshaft Socket 6993 4X2 (3) or Socket
6984 4X4 (3) while installing the fifth gear nut (2)
8. Tighten fifth gear nut as much as possible with
Wrench 6743 (1), long handle ratchet, breaker bar
and applicable socket wrench.
9. Lock mainshaft gears by shifting all synchro
sleeves into engaged position.
10. Tighten fifth gear nut with Nut Wrench 6743 and
high capacity torque wrench. Tighten nut to 366-
380 N·m (270-280 ft. lbs.). Have helper hold
transmission steady if necessary.
11. Torque the fifth gear clamp nut clamping bolt to
13.5 N·m (10 ft. lbs.).
12. Unlock the mainshaft gears by shifting all synchro
sleeves out of the engaged position.
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EXTENSION/ADAPTER HOUSING
1. Clean mating surfaces of extension/adapter hous-
ing (2) and gear case (1) with a wax and grease
remover.
2. Check alignment dowels in gear case and housing
or adapter. Be sure dowels are in position and
seated.
3. Apply Mopar Silicone Sealer or equivalent to gear
case and housing mating surfaces.
4. Align and install extension/adapter housing on gear
case.
5. Apply Mopar Lock N’ Seal or equivalent to threads
of extension/adapter housing bolts.
6. Install and tighten housing bolts to 54 N·m (40 ft.
lbs.).
SHIFT MECHANISM
1. Clean mating surfaces of shift cover and gear case
with wax and grease remover.
2. Apply a small amount of Mopar silicone sealer or
equivalent to sealing surface of shift cover.
CAUTION: Do not over-apply an excessive amount
sealer. Excess can squeezed into gear case and
could block lubricant feed holes in time.
3. Lubricate synchro sleeves with Castrol
T
Syntorq
gear lubricant or equivalent. Then apply light coat
of petroleum jelly to shift fork contact surfaces.
4. Verify shift fork pads (1) are secure.
5. Verify 1-2 and 3-4 synchro sleeves and forks in
shift cover are in neutral position.
6. Align and seat shift cover on transmission.
NOTE: If cover will not seat, it may not be aligned on gear case dowels or shift forks are not aligned with
sleeves and shift lug.
7. Apply Mopar Lock N’ Seal or equivalent to threads of shift cover bolts.
8. Install shift cover bolts and tighten to 27-31 N·m (216-276 in. lbs.).
9. Apply sealer to backup lamp switch. Install switch into cover and tighten to 22-34 N·m (193-265 in. lbs.).
10. Install vent assembly if removed. Apply an adhesive/sealer to vent tube to help secure it in cover.
INSTALLATION
NOTE: If a new transmission is being installed, use all components supplied with the new transmission. For
example, if a new shift tower is supplied with the new transmission, do not re-use the original shift tower.
1. Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of the following
components:
•
input shaft splines.
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•
release bearing slide surface of front retainer.
•
release bearing bore.
•
release fork.
•
release fork ball stud.
•
propeller shaft slip yoke.
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 release bearing and clutch disc hub.
5. Move transmission forward and start input shaft in release bearing, clutch disc and pilot bushing.
6. Work transmission forward until seated against clutch housing. Do not allow transmission to remain unsupported
after input shaft has entered clutch disc.
7. Install transmission bolts and tighten to 108 N·m (80 ft. lbs.).
8. Install transmission mount on transmission or rear crossmember.
9. Install rear crossmember.
10. Remove transmission jack and engine support fixture.
11. Position transmission harness wires in clips on shift cover.
12. Install clutch slave cylinder and install slave cylinder shield, if equipped.
13. Connect speed sensor and backup light switch wires.
TWO WHEEL DRIVE
1. Fill transmission with recommended lubricant. Correct fill level is bottom edge of fill plug hole.
2. Align and install propeller shaft.
3. Lower vehicle.
4. Clean the mating surfaces of shift tower, isolator plate and shift cover with suitable wax and grease remover.
5. Apply Mopar Gasket Maker or equivalent to the sealing surface of the shift cover. Do not over apply sealant.
6. Install the isolator plate onto the shift cover, metal side down.
7. Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and the isolator
plate.
8. Verify that the shift tower, isolator plate and the shift tower bushings are properly aligned.
9. Install the bolts to hold the shift tower to the isolator plate and the shift cover. Tighten the shift tower bolts to
10.2-11.25 N·m (7.5-8.3 ft. lbs.).
10. Install the shift lever extension onto the shift tower and lever assembly.
11. Install shift boot and bezel.
12. Connect battery negative cable.
FOUR WHEEL DRIVE
1. Install transfer case shift mechanism (2) on trans-
mission (1).
2. Install transfer case on transmission jack. Secure
transfer case to jack with safety chains.
3. Raise jack and align transfer case input gear with
transmission mainshaft.
4. Move transfer case forward and seat it on adapter.
5. Install transfer case nuts and tighten to:
•
If 3/8 studs 41-47 N·m (30-35 ft. lbs.).
•
If 5/16 studs 30-41 N·m (22-30 ft. lbs.).
6. Install transfer case shift mechanism to side of
transfer case.
7. Connect transfer case shift lever to range lever on
transfer case.
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8. Align and connect propeller shafts.
9. Fill transmission with required lubricant. Check lubricant level in transfer case and add lubricant if necessary.
10. Install transfer case skid plate, if equipped and crossmember. Tighten attaching bolts/nuts to 41 N·m (30 ft.
lbs.).
11. Install exhaust system components.
12. Lower vehicle.
13. Clean the mating surfaces of shift tower, isolator
plate and shift cover with suitable wax and grease
remover.
14. Apply Mopar Gasket Maker or equivalent to the
sealing surface of the shift cover. Do not over
apply sealant.
15. Install the isolator plate onto the shift cover, metal
side down.
16. Install the shift tower onto the isolator plate. No
sealant is necessary between the shift tower and
the isolator plate.
17. Verify that the shift tower, isolator plate and the
shift tower bushings are properly aligned.
18. Install shift tower (1) bolts (3) and tighten to 10.2-
11.25 N·m (7.5-8.3 ft. lbs.).
19. Install shift lever extension onto the shift tower
and lever assembly and tighten to 47 N·m (35 ft. lbs.).
20. Install shift lever boot and bezel.
21. Connect battery negative cable.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Switch, Back-up Lamp
22-34
16-25
-
Countershaft Bearing
Plate Bolts
19-26
14-19
170-230
Fifth Gear Nut
366-380
270-280
-
Fifth Gear Nut Clamp Bolt
13.5
10
-
Drain and Fill Plug
34-47
25-35
-
Front Bearing Retainer
Bolts
27-34
20-25
235-305
Mainshaft Bearing Plate
Bolts
19-26
14-19
170-230
PTO Cover Bolts
27-54
20-40
-
Extension/Adapter
Housing Bolts
41-68
30-50
-
Shift Mechanism Cover
Bolts
27-31
20-23
-
Shift Lever Extension
47
35
-
Transmission Bolts
108
80
-
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