Part 1 of 2

ASSEMBLY

NOTE: Gaskets are not used in the transmission. Use Mopar Gasket Maker or equivalent on all gear case and extension housing sealing surfaces.

OUTPUT SHAFT
1. Place second gear on bench with the synchro clutch ring up.





2. Install second gear synchro inner blocker ring onto second gear (Fig. 53).





3. Install second gear synchro friction cone over the blocker ring and onto second gear (Fig. 54).





4. Install second gear synchro outer blocker ring over the second gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 55).





5. Install 1-2 synchro assembly onto the second gear assembly (Fig. 56).
6. Reverse assembly on the bench.





7. Install second gear bearing into second gear (Fig. 57).
8. Place completed 1-2 synchro, second gear and second gear bearing to a shop press with second gear facing upward.





9. Install output shaft into the second gear 1-2 synchro assembly with the front of the output shaft facing upward (Fig. 58).
10. Press the output shaft into position.
11. Place first gear on bench with the synchro clutch ring up.
12. Install first gear synchro inner blocker ring onto first gear (Fig. 53).
13. Install first gear synchro, friction cone over the blocker ring and onto first gear (Fig. 54).
14. Install first gear synchro outer blocker ring over the first gear synchro friction cone. Align one of the lugs on the outer ring with a lug on the inner ring (Fig. 55).
15. Reverse the output shaft in the press.
16. Install first gear bearing sleeve onto the output shaft.





17. Install first gear bearing sleeve the remainder of the way onto the output shaft using Installer 8228 and a shop press (Fig. 59).





18. Install first gear and blocker assembly onto the output shaft (Fig. 60).
19. Install first gear bearing over the output shaft and into first gear.





20. Install output shaft thrust washer onto the output shaft (Fig. 61).





21. Install rear output shaft bearing onto the output shaft with Installer 8228 and a shop press (Fig. 62).
22. Install a new snap-ring to hold the rear output bearing onto the output shaft. Select and install the thickest snap-ring which will fit into the groove.
23. Reverse output shaft in the Fixture 8227 and support the shaft with press blocks under first gear.
24. Install sixth gear bearing onto the output shaft.





25. Install sixth gear onto the output shaft and over the sixth gear bearing (Fig. 63).
26. Install the sixth gear friction cone onto sixth gear.





27. Install sixth gear blocker ring over the sixth gear friction cone (Fig. 64).





28. Install Guide 8235 onto the end of the output shaft (Fig. 65).





29. Install 5-6 synchro over Guide 8235 and onto the output shaft (Fig. 66).
30. Press 5-6 synchro, onto the output shaft with Installer 8156 and a shop press.
31. Install output shaft pocket bearing onto the output shaft.





32. Press pocket bearing the remainder of the way onto the output shaft using Guide 8235 and a shop press (Fig. 67).
33. Install a new snap-ring to hold the output shaft pocket bearing onto the output shaft.

COUNTERSHAFT
1. Place third countershaft gear on the bench with the synchro clutch ring up.





2. Install third countershaft gear friction cone onto third gear (Fig. 68).





3. Install third countershaft gear blocker ring onto the friction cone (Fig. 69).





4. Install 3-4 synchro assembly onto the blocker ring/gear assembly (Fig. 70).
5. Reverse the assembly on the bench.
6. Install third countershaft gear bearing into the third countershaft gear.
7. Install 2-3 thrust washer onto the countershaft.
8. Place third gear/3-4 synchro assembly in a shop press.
9. Install countershaft through the third gear/3-4 synchro assembly.





10. Press countershaft into the 3-4 synchro assembly (Fig. 71).
11. Install fourth countershaft gear bearing sleeve onto the output shaft.
12. Press fourth countershaft bearing sleeve onto the countershaft with Installer 8228 and a shop press.
13. Place fourth countershaft gear on the bench with the synchro clutch ring up.
14. Install fourth countershaft gear friction cone onto fourth countershaft gear (Fig. 68).
15. Install fourth countershaft gear blocker ring onto the friction cone (Fig. 69).
16. Install fourth countershaft gear bearing into the fourth countershaft gear.
17. Place sixth countershaft gear in the shop press.





18. Position fourth countershaft gear assembly onto the sixth countershaft gear (Fig. 72).
19. Install countershaft into the fourth/sixth countershaft gear assembly in the shop press.





20. Press countershaft into sixth gear (Fig. 73).
21. Place fifth countershaft gear into the shop press.





22. Install countershaft into the fifth countershaft gear and press countershaft into fifth gear (Fig. 74).

CAUTION: Gear and shaft must be aligned while pressing or the gear will bind on the shaft.

23. Place front countershaft bearing onto the countershaft.
24. Install front countershaft bearing onto the countershaft with Installer 8236 and Handle C-4171.2
25. Install a new snap-ring to hold the front countershaft bearing onto the countershaft.
26. Place rear countershaft, bearing onto the countershaft.

INPUT SHAFT
1. Place the input shaft bearing onto the input shaft.





2. Install input shaft bearing with Installer MD998805 (Fig. 75).





3. Position the input shaft bearing oil guide on the input shaft (Fig. 76).
4. Install input shaft bearing oil guide with Installer MD998805.
5. Place the output shaft pocket bearing race in the input shaft.





6. Install output shaft pocket bearing race into the input shaft with Installer C-4628 and Handle C-4171 (Fig. 77).