Dodge Ram Truck 1500-2500-3500. Manual — part 1536

5. Remove input shaft oil guide (1) and retainer seal

(2).

CLEANING - TRANSMISSION

Clean the gears, bearings shafts, extension/adapter housing and gear case with solvent. Dry all parts except 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.

Inspect the reverse idler gear, bearings, shaft and thrust washers. Replace the bearings if the rollers are worn,
chipped, cracked, flat-spotted or brinnelled. Replace the gear if the teeth are chipped, cracked or worn thin.

Inspect the front bearing retainer and bearing cup. Replace the bearing cup if scored, cracked, brinnelled or rough.
Check the release bearing slide surface of the retainer carefully. Replace the retainer if worn or damaged in any
way.

Inspect mainshaft bearing surfaces, splines, snap ring grooves and threads. Replace the shaft if any surfaces
exhibit considerable wear or damage.

Inspect the countershaft and bearings. Replace the shaft if any surfaces exhibit considerable wear or damage.

Inspect shift forks for wear and distortion. Check fit of the sleeve in the fork to be sure the two parts fit and work
smoothly. Replace the fork if the roll pin holes are worn oversize or damaged. Do not attempt to salvage a worn
fork. Replace shift fork roll pins if necessary or if doubt exists about their condition.

The all bearings for wear, roughness, flat spots, pitting or other damage. Replace the bearings if necessary.

Inspect the blocker rings and fiction cones. replace either part if worn or damaged in any way. Replace if the friction
material is burned, flaking off or worn.

Inspect synchro components wear or damage. Replace parts if worn, cracked or distorted.

Inspect all of the thrust washers and locating pins. Replace the pins if bent or worn. Replace the washers if worn
or the locating pin notches are distorted.

Inspect the case and housing/adapter sealing and mating surfaces are free of burrs and nicks. Inspcet the alignment
dowels in the case top surface and in the housing/adapter are tight and in good condition. Replace the gear case
or housing/adapter if cracked or broken.

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ASSEMBLY

OUTPUT SHAFT

1. Install second gear synchro inner blocker ring (1)

onto second gear (1).

2. Install second gear friction cone (2) over blocker

ring and onto second gear (1).

3. Install second gear outer blocker ring (1) on sec-

ond gear (3) friction cone. Align the lugs on the
outer ring with lugs on the inner ring.

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MANUAL TRANSMISSION - NV5600 - SERVICE INFORMATION

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4. Install 1-2 synchro (1) assembly on second gear

assembly (2).

5. Reverse assembly on the bench.

6. Lubricate and install second gear (2) bearing (1).

7. Place 1-2 synchro (1), second gear (3) with bearing

assembly on shop press with second gear facing
upward.

8. Install output shaft (1) into the second gear 1-2

synchro assembly with the front of the output shaft
facing upward.

9. Press the output shaft into position.

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10. Place first gear on bench with the synchro clutch

ring up.

11. Install first gear synchro inner blocker ring (1) onto

first gear (2).

12. Install first gear synchro friction cone (2) over

blocker ring and onto first gear (1).

13. Install first gear synchro outer blocker ring (1)

over first gear (3) synchro friction cone. Align one
of the lugs (1) on the outer ring with a lug on the
inner ring.

DR/DH

MANUAL TRANSMISSION - NV5600 - SERVICE INFORMATION

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