Part 2 of 2

31. Install reverse gear bearing spacer on mainshaft and seat against reverse clutch gear snap ring (Fig. 100).
32. Install reverse gear bearing on mainshaft (Fig. 100).
33. If reverse gear sleeve and struts were disassembled for service, reassemble sleeve, struts and springs as follows:

CAUTION: The reverse sleeve will fit either way on the hub. Verify tapered side of the sleeve faces rearward.





a. Position sleeve on hub so tapered side of sleeve faces rearward. (Fig. 101).
b. Rotate sleeve to align teeth on sleeve and hub. Sleeve will slide easily into place on hub when properly aligned.
c. Install springs in gear hub (Fig. 101). Use petroleum jelly to hold springs in place if desired.
d. Compress first spring with flat blade screwdriver and slide strut into position in hub slot. Then work spring into seat in strut with small hooked tool or screwdriver.
e. Install second and third struts, in same manner as described in step (d).
f. Work sleeve upward on hub until struts are centered and seated in sleeve. Sleeve should be in neutral position after seating struts.





34. Install reverse gear and synchro assembly on mainshaft (Fig. 102). Rotate assembly until stop ring lugs engage in hub slots and gear drops into seated position.





35. Install reverse gear thrust washer (Fig. 103).





36. Install rear bearing on mainshaft with Installer 6446. Seat bearing on output shaft and against thrust washer (Fig. 104).





37. Install fourth gear stop ring in 3-4 synchro sleeve (Fig. 105).





38. Install fourth gear clutch gear in stop ring (Fig. 106).
39. Roll gear case onto its left side.
40. Grip mainshaft at pilot bearing hub and just behind reverse gear. Then lift assembly and guide rear of shaft through bearing bore at rear of case.
41. Continue holding front of shaft but switch grip at rear to shaft output splines. Lift mainshaft assembly slightly, align gears and seat assembly in case.





42. Set transmission case upright (Fig. 107).





43. Install drive gear thrust bearing on mainshaft (Fig. 108). Use plenty of petroleum jelly to hold bearing in place.
44. Check alignment and mesh of mainshaft gears. If gears are not aligned, roll case on side and realign shaft and gears in case.

DRIVE GEAR AND RETAINER





1. Install bearing on drive gear with Installer 6448 (Fig. 109).
2. Lubricate pilot bearing with petroleum jelly and install it in drive gear bore.
3. Install drive gear on mainshaft. Work gear rearward until mainshaft hub is seated in pilot bearing.





4. Install bearing cup in front retainer with Handle C-4171 and Installer C-4308 (Fig. 110).





5. Install new oil seal in front bearing retainer with Installer 6052 (Fig. 111). Use one or two wood blocks to support retainer as shown. Lubricate seal lip with petroleum jelly after installation.
6. Clean contact surfaces of gear case and front bearing retainer with a wax and grease remover.





7. Apply Mopar Silicone Sealer or equivalent to flange surface of front bearing retainer (Fig. 112).
8. Install front bearing retainer over drive gear and start it into case.
9. Start front bearing retainer in gear case. Verify retainer lube channel is at the top-center (12 O'clock) position (Fig. 112).





10. Align front bearing retainer bolt holes and tap retainer into place with plastic mallet. Install new retainer bolts and tighten to 30 Nm (22 ft. lbs.) (Fig. 113).

NOTE: Never reuse the old bolts.

MAINSHAFT END PLAY
1. Install mainshaft rear bearing cup in case and over bearing. Tap bearing cup into place with plastic mallet.





2. Install rear bearing plate to hold mainshaft and rear bearing in position (Fig. 114).

NOTE: Do not install any end play shims at this time.

3. Tighten rear bearing plate bolts securely
4. Place gear case in upright position on bench. Either cut hole in bench to accept drive gear and front retainer or use C-clamps to secure transmission on bench.

NOTE: Do not leave transmission unsupported.

5. Install Extension Rod 8161 into a suitable threaded hole in rear of case.
6. Mount dial indicator on extension rod and position indicator plunger against end of mainshaft.
7. Move mainshaft forward to remove all play then zero dial indicator.
8. Move mainshaft upward and record dial indicator reading. Move mainshaft with pry tool positioned between drive gear and case.
9. End play should be 0.051 - 0.15 mm, (0.002 - 0.006 inch). Select fit shims are available to adjust end play. If end play adjustment is required, remove bearing plate and install necessary shim.
10. Reinstall rear bearing plate with oil hole in bearing plate at the top (Fig. 114).
11. Apply Mopar Lock N' Seal or equivalent to bearing plate bolt threads. Install and tighten bolts to 23 Nm (200 inch lbs.).





12. Install mainshaft fifth gear with Installer 6446 (Fig. 115). Gear is seated when it contacts rear bearing.

COUNTERSHAFT FIFTH GEAR SYNCHRO





1. Install thrust washer pin in countershaft (Fig. 116).





2. Install thrust washer on countershaft. Turn washer until pin engages in washer notch (Fig. 117).

NOTE: The flat side of washer faces the rear and cone side faces the front.





3. Lubricate and install fifth gear bearing on countershaft (Fig. 118).





4. Install synchro sleeve on hub of countershaft fifth gear with tapered side of sleeve facing front and the flat side facing rear (Fig. 119).





5. Install shift fork in synchro sleeve (Fig. 120).





6. Install assembled fifth gear, synchro sleeve and shift fork (Fig. 121). Align fork with shift lug rail and align gear with bearings and countershaft. Start components onto shaft and rail, then tap gear and fork into place with plastic or rawhide mallet.





7. Install fifth gear synchro struts and springs (Fig. 122).





8. Assemble and install fifth synchro clutch gear and stop ring in fifth gear hub (Fig. 123). Verify parts are seated in fifth gear hub.





9. Install clutch gear snap ring (Fig. 124).
10. Align roll pin holes in shift fork with notches in shift lug rail. Then install roll pins from top side of fork (Fig. 121).

NOTE: Roll pins only fit one way due to small shoulder at one end of each pin.

FIFTH GEAR NUT
1. Install belleville washer onto the mainshaft.
2. Install fifth gear nut over the mainshaft.
3. refighting the clamp bolt until the gap in the clamp nut assembly is closed.
4. Back the clamp bolt off one full turn.
5. Place 10-15 drops of Loctite Tm 272 onto the mainshaft threads where the fifth gear nut will be engaged.





6. Install fifth gear nut on mainshaft (Fig. 125).
7. There are two splined sockets available to retain the mainshaft while installing the fifth gear nut.
^ 4X2 mainshafts Socket 6993
^ 4X4 mainshafts Socket 6984





8. Tighten fifth gear nut as much as possible with Nut Wrench 6743, long handle ratchet, breaker bar and applicable socket wrench (Fig. 126).
9. Lock mainshaft gears by shifting all synchro sleeves into engaged position.
10. Tighten fifth gear nut with Nut Wrench 6743 and high capacity torque wrench. Tighten nut to 366 - 380 Nm (270 - 280 ft. lbs.). Have helper hold transmission steady if necessary.
11. Torque the fifth gear clamp nut clamping bolt to 13.5 Nm (10 ft. lbs.).
12. Unlock the mainshaft gears by shifting all synchro sleeves out of the engaged position.

EXTENSION/ADAPTER HOUSING
1. Clean mating surfaces of extension/adapter housing and gear case with a wax and grease remover.
2. Check alignment dowels in gear case and housing or adapter. Be sure dowels are in position and seated.
3. Apply Mopar Silicone Sealer or equivalent to gear case and housing mating surfaces.





4. Align and install extension/adapter housing on gear case (Fig. 127).
5. Apply Mopar Lock N' Seal or equivalent to threads of extension/adapter housing bolts.
6. Install and tighten housing bolts to 54 Nm (40 ft. lbs.).
7. Install transfer case, if equipped.
8. Install engine rear support. Refer to 9 Engine for procedures.
9. Install propeller shaft(s).
10. Remove transmission support stand and lower vehicle.