|DodgeRam.org > Main > Tech Index > Specs > NV5600 > Design and Features > Page 5|
|MASTERTECH No. 11 November 1998 - Page 5|
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for Truck accessories.
Be aware that no gaskets are used anywhere in the NV5600. Use Mopar Gasket Maker when joining two components that require a good seal.
You should pre-lube the thrust faces for second and sixth gears on the mainshaft with a suitable lubricant, such as wheel bearing grease, beforere assembling it. You should also pre-lube the sixth countershaft gear thrust face on the fourth speed gear side. And pre-lube all bearings and synchronizer friction rings with Mopar manual transmission lubricant before installing them.
The synchronizer assemblies have alternating high and low areas on the friction rings and clutch rings (Fig 21).
When assembling the single-cone synchros, make sure that the high area on the friction ring is seated in the high area on the clutch ring.
On the dual-cone 1-2 synchronizer assembly, be sure you have the high areas on the friction ring seated in the low areas on the clutch ring. If they aren't assembled correctly, the synchronizers won't work, resulting in gear clash.
Another item to watch for during assembly is shift arm position at the primary shift rail. Be sure the match the position you noted before disassembly. The shift arm closest to the geartrain should be for reverse. Moving out from the geartrain, the shift arms should be for 5th and 6th gear, than 3rd and 4th gear, with the 1st and 2nd gear shift arms being furthest from the geartrain (Fig 22).
Using the appropriate special tools, install the bearing races for the input shaft and countershaft. These races are installed above the surface of the clutch housing to ensure shim clearance.
Because the mainshaft and countershaft endplay and adjustment is critical to NV5600 operation, we'll look at the procedure in some detail. Remember to consult the service manual for complete instruction.
Before making endplay measurements, rotate the mainshaft several times to seat the bearings in the races. Measure the main and countershaft endplay with special tool C-3339, which is a dial indicator set and special tool 8161, an extension rod (Fig 23).
|Shims for the mainshaft are installed into the input shaft retainer,
while countershaft shims are installed between the bearing race and space
(Fig 24). After the shims are installed, verify that the endplay is within
specification by taking another measurement.
The measurement is taken at the rear of the transmission, and the proper endplay for the mainshaft and countershaft should be 0.002" to 0.006" (0.051 to 0.150 millimeters).
hen installing a new output shaft nut, you must use the correct
size punch to stake the nut in the slot in the output shaft. Use a punch that
has a diameter of approximately 5/16" or 9mm to stake the output shaft
|During reassembly, it's important that you make sure all lubrication oil passages are free from excess sealant. This is especially crucial for the passage that feeds the pocket bearing between the input and output shaft (Fig 25). This bearing could be damaged if the lube passage is blocked.|
You can see that the NV5600 has many special tools used for removal, disassembly,
and reassembly, so be sure to familiarize yourself with them. A complete list
of special tools can be found at the end of the NV5600 section in Group 21 of
the Ram Truck Service Manual.
Thanks to Bob Bergevin for his help with this page.
Last Update: September 6, 1999