RAM 2500 Truck 2WD L6-359 5.9L DSL Turbo VIN D FI (1997)
49.
Install the fifth gear synchronizer thrust washer pin into the countershaft bore (Figure 17).
50.
Install the fifth gear synchronizer thrust washer onto the countershaft. The flat side of the washer faces the rear of the transmission and the tapered
side faces the front of the transmission (Figure 17). Turn the washer until the pin engages into the thrust washer notch.
51.
Lubricate the fifth gear needle bearing with gear Mopar NV 4500 Transmission Lubricant p/n 04874459 and install the bearing onto the
countershaft.
52.
Install fifth gear shift fork, gear and hub, and synchronizer components as an assembly onto the countershaft and the shift rail.
53.
Install clutch gear snap ring (Figure 9).
54.
Align roll pin holes in shift fork with notches in the shift lug rail. Then, install roll pins from top side of the fork.
NOTE:
ROLL PINS ARE DIRECTIONAL AND WILL ONLY FIT PROPERLY ONE WAY DUE TO A SMALLER SHOULDER AT ONE END OF THE
PIN.
55.
Verify that the alignment dowels in gear case and extension/adapter housing are in their proper position and are fully seated.
56.
Apply Mopar Gasket Maker p/n 04318083 to the gear case and extension/adapter housing mating surfaces.
57.
Align and install the extension/adapter housing onto the gear case.
58.
Apply Mopar Lock N' Seal p/n 04318031 to the threads of the extension/adapter housing bolts.
59.
Install and tighten the housing bolts to 54 N.m (40 ft. lbs).
60.
Continue reassembly procedures using Steps 1 through 23 in reverse order.
61.
Once the transmission has been fully assembled, fill the transmission with 3.78 liters (8 pints) Mopar NV 4500 Transmission Lubricant p/n
04874459.
