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TSB 21-04-94

Transmission Shift Lever Stuck in or Blocked Out of 5th or Reverse Gear

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Date: Mar. 4, 1994

Models: 1992 - 1993 (AD) Ram Pickup, Chassis Cab       1994 (BR) Ram Truck

NOTE: This bulletin applies to vehicles equipped with NV4500 and
NV4500HD Manual Transmission

Symptoms:

Transmission shift lever does not shift out of 5th gear or reverse gear positions, or
the shift lever will not go into 5th gear or reverse. The condition may be constant
or intermittent.  

Diagnosis: 

REVERSE BLOCK OUT:

Start the engine with the transmission in Neutral. With the engine at low idle
speed, shift the transmission  reverse. If the transmission shifts into reverse,
shift back into neutral. If the transmission shifts into neutral, shift back into
reverse and back the vehicle up about a foot. Repeat this shifting/backing up
sequence 7 times. If the shift effort at any time becomes extremely high, or
the lever sticks, or the shift is blocked out, proceed to the repair procedure.

SHIFT LEVER STICKS IN 5TH GEAR:

Road test the vehicle under normal vehicle operating conditions and speed to
properly shift into 5th gear. Shift into 5th gear and then shift into neutral.
(CAUTION: Make sure traffic and road conditions are safe to use this procedure.)
Repeat this shifting sequence 7 times. (Make sure that road speed is fast enough to
properly shift into 5th gear each time). If the shift effort becomes extremely high, or
the shift lever sticks, or the shift lever blocks out of 5th gear, proceed to the repair
procedure.

Parts Required: 

1   4778218  Package - Transmission 5th/Reverse Shift Improvement
                     Consists of:

     1    4778216   Rail - Overdrive Lug and Fork
     1    4773178   Fork - Overdrive Shift
     1    4637692   Lug - Overdrive
     3    4741362   Pin
     1    4723002   Assembly - Overdrive Synchronizer
     8    4637805   Screw - Rear Retainer
     1    4637795   Ring - Retainer

Repair Procedure: 

This bulletin involves replacement of the transmission overdrive rail, lug shift fork,
and synchronizer assembly with revised parts.
1.       Following the procedures listed in the appropriate service manual, drain the
transmission fluid and remove the transmission from the vehicle.
2. Remove the rear extension from the transmission. Discard the extension bolts.
3. Remove the overdrive snap ring that retains the overdrive clutch gear,
synchronizer ring, and synchronizer assembly on the countershaft. Discard
the snap ring.
4. Remove the shift cover assembly from the transmission case.
5. Remove the O.D. lug by driving out the roll pin that retains the O.D. lug
to the O.D. rail. Discard the roll pin.
6. Slide out the O.D. rail/fork assembly, clutch gear, synchronizer ring, and
synchronizer assembly from the transmission.
7. Discard the O.D. rail/fork assembly and the synchronizer assembly.
8. Install new synchronizer assembly (P/N 4773002) onto the countershaft.
9. Install new O.D. shift fork (P/N 4778216) through the fork and into the
transmission case. Install new O.D. lug (P/N 4637692) onto the O.D.
rail inside the transmission case.
10. Install the synchronizer ring and clutch gear back onto the countershaft.
11. Drive 2 new roll pins (P/N 4741362) into the fork and rail to join them
together. Drive one roll pin into the lug and rail to join them together.
12. Install new retainer ring (P/N 4637795) onto the countershaft.
13. Clean mating surfaces of the extension housing, shift cover and
gear case with a wax and grease remover such as Mopar Super
Kleen (P/N 4318015).
14. Apply Mopar Gasket Maker (P/N 4318083) to gear case, shift cover, and
extension housing surfaces.
15. Align and install the extension housing on the gear case. NOTE: Use new
extension housing bolts. Apply Mopar Lock N' Seal P/N 4318031 or Loctite 242
to the threads and tighten to 54Nm (40 ft. lbs.) torque. Use a twelve point 10 mm
socket.
16. Align and install the shift cover on the gear case. Apply Mopar Lock N' Seal
P/N 4318031 or Loctite 242 to the threads and tighten to 30Nm (265 in. lbs.) torque.
17. Fill the transmission to the bottom edge of the fill plug hole with Mopar
Manual Transmission Lubricant, (P/N 4637579) or Castrol Syntorq.
18. Follow the procedure listed in the appropriate service manual and install the
transmission in the vehicle.

Notes: 

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No: 
21-36-03-91   1994 BR  . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hrs.
      21-00-03-61   4x4 Equipped . . . . . . .. . . . . . . . . . . 1.7 Hrs.
      21-00-03-60   Skid Plate Equipped  . . . . . . .. . . . . . 0.4 Hrs.
      21-00-03-62   Two Piece Prop. Shaft . . . . . .. . . . . . 0.2 Hrs.

21-36-03-92   1992 - 1993 AD 2W/D  . . . . . . . . . . . . 3.3 Hrs.
21-36-03-93   1992 - 1993 AD 4W/D  . . . . . . . . . . . . 1.3 Hrs.
      21-00-03-60   Skid Plate Equipped  . . . . . . .. . . . . . 0.3 Hrs.
      21-00-03-62   Two Piece Prop. Shaft . . . . . .. . . . . . 0.2 Hrs.
      21-00-03-63   Dual Exhaust Equipped . . . . . . . . . . . 0.3 Hrs.  

Failure Code:  P8 - New Part 


Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information

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This page was edited on: February 13, 2008