Assembly
BEARING AND SEAL REPLACEMENTFig. 49:
1. Using Remover C-4210 and Handle C-4171 drive input shaft bearing from case from inside annulus gear opening (Fig. 49).
2. Install locating ring on new bearing.
3. Position case so that the forward end is facing upward.
Fig. 50:
4. Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring must be fully seated on case (Fig. 50).
5. Using Installer 6953, remove front output shaft bearing.
Fig. 51:
6. Start front shaft output bearing in case (Fig. 51). Then seat bearing with Handle C-4171 and Installer 6953.
Fig. 52:
7. Install front output bearing retaining ring.
8. Install new front output seal in front case with Installer Tool 6888 and Tool Handle C-4171 as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.
Fig. 53:
b. Start seal in bore with light taps from hammer (Fig. 53). Once seal is started, continue tapping seal into bore until installer tool bottoms against case.
Fig. 54:
c. Remove installer and verify that seal is recessed the proper amount. Seal should be 2.03 to 2.5 mm (0.080 to 0.100 inch) below top edge of seal bore in front case (Fig. 54). This is correct final seal position.
CAUTION: Be sure the front output seal is seated below the top edge of the case bore as shown. The seal could loosen, or become cocked if not seated to recommended depth.
9. Remove seal from front bearing retainer with suitable pry tool.
10. Install new oil seal in front bearing retainer with Installer 7884 (Fig. 54).
11. Remove seal from oil pump with suitable pry tool.
Fig. 55:
12. Install new seal in oil pump with Installer 7888 (Fig. 55).
Fig. 56:
13. Inspect carrier needle bearing. If bearing is worn, rough, or damaged in any way, remove it with a brass punch and hammer (Fig. 56).
Fig. 57:
14. Install new needle bearing in planetary carrier (Fig. 57). Use Handle C-4171 and Installer 5062 to install bearing.
Fig. 58:
15. Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (Fig. 58).
16. Install new pilot bearing with Plug C-293-3.
Fig. 59:
17. Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 (Fig. 59).
Fig. 60:
Fig. 61:
18. Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 60). The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (Fig. 61).
INPUT AND PLANETARY GEAR ASSEMBLY
1. Lubricate planetary components with transmission fluid.
Fig. 62:
2. Install first thrust washer in carrier (Fig. 62). Lube washer with petroleum jelly before installation.
Fig. 63:
3. Support carrier with wood blocks under PTO gear (Fig. 63).
4. Install support sleeve in planetary carrier. Be sure sleeve is seated.
Fig. 64:
5. Install input gear in planetary carrier (Fig. 64).
6. Install second thrust washer in planetary carrier. Be sure washer tabs are seated in carrier slots.
Fig. 65:
7. Install lock ring (Fig. 65).
Fig. 66:
8. Install retaining ring (Fig. 66).
INPUT AND PLANETARY GEAR INSTALLATION
1. Lubricate planetary pinions and annulus gear with transmission fluid.
Fig. 67:
2. Install planetary/input gear assembly in case (Fig. 67).
3. Start planetary pinions in low range annulus gear. Then tap PTO gear, with hammer handle to seat planetary pinions in annulus gear.
Fig. 68:
4. Install retaining ring on input gear (Fig. 68).
5. Apply bead of Mopar@ Gasket Maker, or equivalent, to mating surface of input retainer. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into oil channel and feed hole in case.
Fig. 69:
6. Align oil channel in retainer with oil feed hole in front case (Fig. 69).
Fig. 70:
7. Install retainer on input gear shaft and front case (Fig. 70).
8. Apply Mopar silicone sealer to threads of input retainer bolts. Then install and tighten bolts to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
MAINSHAFT ASSEMBLY
Fig. 71:
1. Install drive sprocket on mainshaft (Fig. 71).
Fig. 72:
2. Install brass stop ring on drive sprocket (Fig. 72).
3. Install 3 synchro struts and 2 springs in hub as follows:
Fig. 73:
a. Insert first strut in hub (Fig. 73). Strut shoulders rest (and slide) on sides hub slot as shown.
Fig. 74:
b. Insert hooked end of first spring in center of strut to secure it. Then work spring into hub (Fig. 74).
Fig. 75:
c. Press spring inward and insert last two struts in hub slots. Be sure spring is positioned under struts to properly secure them (Fig. 75).
d. Turn hub over and install remaining spring in hub. Position hooked end of second spring 180° away from first spring end.
Fig. 76:
4. Install assembled synchro hub on mainshaft; (Fig. 76). Hub has shoulder on one side which goes toward sprocket (rear of shaft). Flat side of hub faces front of shaft.
Fig. 77:
5. Install synchro hub retaining ring (Fig. 77). Be sure ring is fully seated before proceeding.
Fig. 78:
6. Install sliding clutch (sleeve) on synchro hub (Fig. 78).
Fig. 79:
CAUTION: The sliding clutch must be correctly positioned to ensure proper shifting. Position the clutch on the hub so a clutch spline is centered over each strut as shown (Fig. 79). If the clutch is installed so a gap between splines is aligned with one or more struts, gear clash will result.
SHIFT FORKS AND MAINSHAFT INSTALLATION
1. Support front case on wood blocks so case interior is facing up. Place blocks between mounting studs on forward surface of case. Be sure blocks will not interfere with input gear installation.
2. Lubricate mainshaft components with Dexron II transmission fluid.
Fig. 80:
3. Lubricate sector shaft with transmission fluid and install shift sector in case (Fig. 80). Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.
Fig. 81:
Fig. 82:
4. Assemble range fork and synchro clutch and hub (Fig. 81). Then install fork and hub in case. Seat hub on support sleeve and seat range fork pin in shift sector slot (Fig. 82).
Fig. 83:
5. Install sliding hub and retaining ring (Fig. 83). Be sure ring is fully seated before proceeding.
Fig. 84:
6. Install mode fork and shift rail in sliding clutch (Fig. 84).
Fig. 85:
7. Install mainshaft/mode fork assembly (Fig. 85). Guide mainshaft through hub and into input gear and shift rail through range fork and into case bore.
Fig. 86:
8. Install vacuum/indicator switch (Fig. 86). Tighten switch to 20 - 34 Nm (15 - 25 ft. lbs.) torque. Install new O-ring on switch beforehand, if necessary.
Fig. 87:
9. Install new sector shaft O-ring and O-ring retainer in sector shaft bore (Fig. 87). Lubricate O-ring with transmission fluid or petroleum jelly after installation.
Fig. 88:
10. Install shift lever on sector shaft (Fig. 88).
11. Install washer and nut on sector shaft to secure shift lever. Apply 1-2 drops Mopar Lock N' Seal, or equivalent, to nut threads before installation. Then tighten nut to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
Fig. 89:
12. Install poppet plunger and spring (Fig. 89).
Fig. 90:
13. Install new O-ring on poppet screw and install screw in front case (Fig. 90). Tighten screw to 16 - 24 Nm (12 - 18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
Fig. 91:
1. Install front output shaft in bearing (Fig. 91).
Fig. 92:
2. Insert front sprocket in drive chain (Fig. 92).
3. Install drive chain around mainshaft sprocket (Fig. 92). Then position front sprocket over front shaft.
4. Raise mainshaft about 2.54 cm (1 inch) and seat front sprocket on front output shaft.
5. If mainshaft and sliding clutch were unseated during chain installation, align and reseat mainshaft in input gear and hub. Then reseat synchro hub in sliding clutch. Press synchro struts inward to ease clutch back onto hub.
Fig. 93:
6. Install front sprocket retaining ring (Fig. 93).
7. Realign sliding clutch on synchro hub if necessary. Press synchro struts inward to ease realignment. Be sure mainshaft is fully seated before proceeding.
Fig. 94:
8. Install spring and cup on shift rail (Fig. 94).
Fig. 95:
9. Insert magnet in front case pocket (Fig. 95).
OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION
96:
Lubricate the oil pump components with Dexron II before installation. Prime the oil pickup tube by pouring a little oil into the tube before installation.
Fig. 97:
2. Position oil pickup tube and filter in rear case. Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches (Fig. 97). Be sure hose that connects tube to filter is securely positioned.
Fig. 98:
3. Insert oil pickup tube in oil pump and position pump in rear case (Fig. 98).
4. Apply bead of Mopar Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
Fig. 99:
5. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case and oil pump assembly (Fig. 99). Be sure oil pump and pickup tube remain in position during case installation.
6. Install 4-5 rear case-to front case bolts to hold rear case in position. Tighten bolts snug but not to specified torque at this time.
Fig. 100:
CAUTION: Verify that shift rail (Fig. 100), and case alignment dowels are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.
7. Verify that oil pump is aligned and seated on rear case. Reposition pump if necessary.
Fig. 101:
8. Check stud at end of case halves (Fig. 101). If stud was loosened or came out during disassembly, apply Loctite 242 to stud threads and reseat stud in case.
9. Apply Loctite 242 to remainder of rear case-to-front case bolt threads and install bolts. Be sure lock washers are used on studs/bolts at case ends. Tighten bolts, or stud nuts as follows:
^ flange head bolts to 47 - 61 Nm (35 - 45 ft. lbs.)
^ all other bolts/nuts to 27 - 34 Nm (20 - 25 ft. lbs.)
Fig. 102:
10. Install oil pump retaining ring on mainshaft (Fig. 102).
11. Install rear output bearing and snap ring to output shaft.
COMPANION FLANGE INSTALLATION
Fig. 103:
1. Install companion flange seal on front shaft (Fig. 103).
Fig. 104:
2. Install companion flange on front shaft (Fig. 104). Then install and tighten flange nut to 176 - 271 Nm (130 - 200 ft. lbs.) torque.
EXTENSION HOUSING AND PTO COVER
1. Apply bead of Mopar Gasket Maker, or equivalent, to mating surface of extension housing. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into oil pump.
2. Position extension housing over output shaft.
3. Spread extension housing retaining ring and seat extension housing on rear case. Verify that the retaining ring is seated in output shaft rear bearing.
4. Install retaining ring access cover.
5. Apply Mopar silicone sealer, or equivalent, to threads of extension housing bolts. Then install bolts finger tight.
6. Tighten extension housing bolts to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
7. Apply Mopar silicone adhesive/sealer to mating surface of PTO cover and to cover bolt shanks and underside of bolt heads. Then install and tighten bolts to 27 - 34 Nm (20 - 25 ft. lbs.) torque.