Assembly

CLEANING - TRANSMISSION
Clean the gears, bearings shafts, extension/adapter housing and gear case with solvent. Dry all parts except the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.

INSPECTION

NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and polished out with crocus cloth. Inspect the reverse idler gear, bearings, shaft and thrust washers. Replace the bearings if the rollers are worn, chipped, cracked, flat-spotted or brinnelled. Replace the gear if the teeth are chipped, cracked or worn thin. Inspect the front bearing retainer and bearing cup. Replace the bearing cup if scored, cracked, brinnelled or rough. Check the release bearing slide surface of the retainer carefully. Replace the retainer if worn or damaged in any way. Inspect mainshaft bearing surfaces, splines, snap ring grooves and threads. Replace the shaft if any surfaces exhibit considerable wear or damage.

Inspect the countershaft and bearings. Replace the shaft if any surfaces exhibit considerable wear or damage. Inspect shift forks for wear and distortion. Check fit of the sleeve in the fork to be sure the two parts fit and work smoothly. Replace the fork if the roll pin holes are worn oversize or damaged. Do not attempt to salvage a worn fork. Replace shift fork roll pins if necessary or if doubt exists about their condition. The all bearings for wear, roughness, flat spots, pitting or other damage. Replace the bearings if necessary. Inspect the blocker rings and fiction cones. replace either part if worn or damaged in any way. Replace if the friction material is burned, flaking off or worn. Inspect synchro components wear or damage. Replace parts if worn, cracked or distorted. Inspect all of the thrust washers and locating pins. Replace the pins if bent or worn. Replace the washers if worn or the locating pin notches are distorted. Inspect the case and housing/adapter sealing and mating surfaces are free of burrs and nicks. Inspect the alignment dowels in the case top surface and in the housing/adapter are tight and in good condition. Replace the gear case or housing/adapter if cracked or broken.

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. 51).





3. Install second gear synchro friction cone over the blocker ring and onto second gear (Fig. 52).





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. 53).





5. Install 1-2 synchro assembly onto the second gear assembly (Fig. 54).
6. Reverse assembly on the bench.





7. Lubricate and install second gear bearing into second gear (Fig. 55).
8. Place 1-2 synchro, second gear and second gear bearing assembly on 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. 56).
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. 51).
13. Install first gear synchro friction cone over the blocker ring and onto first gear (Fig. 52).
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. 53).
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. 57).





18. Install first gear and blocker assembly onto the output shaft (Fig. 58).
19. Install first gear bearing over the output shaft and into first gear.





20. Install output shaft thrust washer onto the output shaft (Fig. 59).





21. Install rear output shaft bearing onto the output shaft with Installer 8228 and a shop press (Fig. 60).
22. Install a new snap-ring to hold the rear output bearing onto the output shaft. 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. 61).
26. Install the sixth gear friction cone onto sixth gear.





27. Install sixth gear blocker ring over the sixth gear friction cone (Fig. 62).





28. Install Guide 8235 onto the end of the output shaft (Fig. 63).
29. Install 5-6 synchro over Guide 8235 and onto the output shaft.





30. Press 5-6 synchro (Fig. 64) 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. 65).
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. 66).





3. Install third countershaft gear blocker ring onto the friction cone (Fig. 67).





4. Install 3-4 synchro assembly onto the blocker ring/gear assembly (Fig. 68).
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. 69).
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. 66).
15. Install fourth countershaft gear blocker ring onto the friction cone (Fig. 67).
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. 70).
19. Install countershaft into the fourth/sixth countershaft gear assembly in the shop press.





20. Press countershaft into sixth gear (Fig. 71).

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

21. Place fifth countershaft gear into the shop press.





22. Install countershaft into the fifth countershaft gear and press countershaft into fifth gear (Fig. 72).

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.
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. 73).





3. Position the input shaft bearing oil guide on the input shaft (Fig. 74).
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. 75).

CLUTCH HOUSING
1. Install input shaft bearing race so that the bearing race protrudes 0.3 inch above the front surface of the clutch housing. Install bearing race with Remover/Installer 8237 and Handle C-4171.
2. Install countershaft front bearing race into the clutch housing so that the bearing race protrudes 0.4 inch above the front surface of the clutch housing. Install bearing race with Remover 6061-1 and Handle C-4171.





3. Install countershaft oil guide and spacer into the countershaft front bearing bore in the clutch housing (Fig. 76).
4. Clean all old sealer from the input shaft retainer and the clutch housing but DO NOT apply new sealer at this time. New sealer will be applied after all the preload measurements are made and end-play shims are installed.

NOTE: Do not replace the input shaft seal at this time. A new seal will be installed after all the preload measurements are made and endplay shims are installed.

5. Install input shaft retainer onto the clutch housing and install bolts to hold the input shaft retainer.

GEARTRAIN
1. Install input shaft into Support Stand 8246.
2. Install fifth gear friction cone onto the input shaft.
3. Install fifth gear blocker ring onto the fifth gear friction cone.





4. Install output shaft into the input shaft (Fig. 77).





5. Install countershaft into the Support Stand 8246 and verify that all gears are meshed with their mates on the output shaft (Fig. 78).
6. Install Fixture 8232 to the output shaft and countershaft.
7. Install Holding Tool 8242 onto the 5-6 synchro and tighten the screw to hold the 5-6 synchro together during the remainder of the installation procedure.





8. Attach a engine crane or equivalent to Fixture 8232 and move the geartrain from the Support Stand 8246 to the clutch housing (Fig. 79).





9. Install shift forks and rails onto the geartrain (Fig. 80).

NOTE: The closest shift arm to the geartrain is for Reverse. The next is 5-6, then 3-4 and then 1-2 when moving out from the geartrain.

10. Install geartrain and shift rails into the clutch housing. Lower the geartrain and rails into the housing slowly while guiding input shaft through input shaft seal. Avoid any binds on the shift rails, forks and synchros as the rails enter their bushings.

CAUTION: Do not damage input shaft seal with the input shaft splines.





11. With the geartrain approximately 1/4 inch from the clutch housing, remove Holding Tool 8242 from the 5-6 synchro (Fig. 81).
12. Install 5-6 crossover bracket and arm to the shift rails and the clutch housing.
13. Lower geartrain the remainder of the way into the clutch housing.





14. Install the 5-6 crossover bracket bolts and tighten to 28 Nm (20 ft. lbs.) (Fig. 82).
15. Remove engine crane and Fixture 8232 from the output shaft and the countershaft.

TRANSMISSION GEAR CASE
1. Install rear output shaft bearing race into the transmission gear case with Installer C-4308 and Handle C-4171.
2. Install rear countershaft bearing race into the transmission gear case with Installer 8153 and Handle C-4171.
3. Install Fixture 8232 to the transmission gear case.

NOTE: Shift socket must be loose on the shift shaft and is rotated a minimum of 900 from its normal position. This will ensure enough clearance to install the transmission gear case.

4. Apply sealant to the clutch housing.





5. Attach an engine crane or equivalent to Fixture 8232 and install the transmission gear case onto the clutch housing (Fig. 83).
6. Install clutch housing bolts and tighten to 48 Nm (35 ft. lbs.).
7. Install shift socket roll pin with a suitable 6 mm (7/32 inch) punch and hammer.

MAINSHAFT AND COUNTERSHAFT ENDPLAY
1. With transmission in vertical position, use Socket 6993 to rotate the shafts and seat the bearings.





2. Measure mainshaft endplay with Dial Indicator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case (Fig. 84).





3. Measure countershaft end-play with Dial Indicator Set C-3339 and Extension Rod 8161 installed onto the rear of the transmission gear case (Fig. 85).
4. Rotate transmission into a horizontal position and remove the input shaft retainer.
5. Install shims necessary to achieve an end-play of 0 - 0.10 mm (0 - 0.004 inch) for the mainshaft and countershaft.

NOTE: Countershaft shims go between the bearing race and spacer. Mainshaft shims go into the input shaft retainer.

6. Install a new input shaft seal into the input shaft retainer with Installer C-4965.
7. Install input shaft oil guide with C-3972-A and Handle C-417 1.
8. Apply sealer to the input shaft retainer and install retainer onto the clutch housing. Install bolts and tighten to 28 Nm (20 ft. lbs.).

REVERSE GEAR





1. Install reverse shift fork and synchronizer as an assembly onto the reverse shift rail and output shaft (Fig. 86).

NOTE: Raised square shoulder and snap-ring on the synchro face the case.

2. Install roll-pin securing the reverse shift fork to the reverse shift rail with 6 mm (7/32 inch) punch and a hammer.





3. Install reverse gear bearing sleeve onto the output shaft with Installer 6446 if necessary (Fig. 87).





4. Install reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring and reverse gear bearing (Fig. 88).





5. Install output shaft ball bearing assembly and reverse thrust washer onto the output shaft (Fig. 89).

NOTE: Raised shoulder on thrust washer faces away from the reverse gear.

6. Install a new output shaft nut onto the output shaft.
7. With Wrench 8226 on the output shaft nut and Socket 6993 or 6984 holding the output shaft, tighten the nut to 339 Nm (250 ft. lbs.).
8. Stake nut into the slot in the output shaft with a 9 mm (5/16 inch) punch.
9. Press countershaft reverse gear into the sleeve with a shop press.
10. Install reverse countershaft rear bearing onto the countershaft reverse gear assembly with Installer C-4652 and Handle C-4171.
11. Install reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer onto the idler gear shaft.





12. Install idler and reverse countershaft gears together (Fig. 90).
13. Install reverse idler thrust washer from the reverse idler.





14. Install crossover cam rollers and pin (Fig. 91).

EXTENSION ADAPTER HOUSING
1. Install extension housing bushing with Installer 8156 and Handle C-4171, if necessary. The oil feed hole must be at the 12 o'clock position when installed.
2. On 4X2 vehicles, install extension housing seal with Installer 8154 and Handle C-4171, with the weep hole at the bottom.

NOTE: Drain hole located in the dust boot portion of the seal must face downward (toward the ground) when installed.

3. On 4X4 vehicles, install adapter housing seal with Installer C-3860-A and Handle C-4171.
4. Install the crossover cam bushing into the extension/adapter housing with Installer 8239 and Handle C-4171.
5. Clean the rear of the transmission case of all sealer.
6. Install reverse countershaft gear bearing race onto the reverse countershaft gear bearing.





7. Measure the distance from the back of the bearing race to Gauge Bar 6311 (Fig. 92).
8. Measure thickness of the gauge bar and record the total of the two measurements.
9. Clean all the sealer from the extension/adapter housing.





10. Place Gauge Bar 6311 across the housing face. Measure the distance from the top of the bar to the bottom of the reverse countershaft bearing race bore (Fig. 93).
11. Subtract thickness of the gauge bar from the measurement and record the result.
12. The difference between the two measurements is the end-play for the reverse countershaft gear assembly.
13. Install shims to achieve 0.15 - 0.25 mm (0.006 - 0.010 inch) end-play for the reverse countershaft gear assembly into the reverse countershaft bearing race bore.
14. Use Installer to install the reverse countershaft bearing race into the extension/adapter housing.
15. Install back-up lamp switch into the extension/adapter housing and tighten to 28 Nm (20 ft. lbs.).
16. Install crossover cam into the extension/ adapter housing.





17. Install bolt to hold the crossover cam to the extension/adapter housing (Fig. 94).





18. Install crossover detent plunger, spring and plug into the extension/adapter housing. Tighten the plug to 47.5 Nm (35 ft. lbs.) (Fig. 95).
19. Apply sealer to the surface of the transmission case.
20. Install extension/adapter housing onto the transmission case.
21. Install bolts to hold the extension/adapter housing onto the transmission gear case. Tighten bolts to 48 Nm (35 ft. lbs.).
22. Install shift rail blocker bolt and tighten bolt to 55 Nm (41 ft. lbs.).
23. Install primary shift rail detent plunger, spring and plug into the transmission case. Tighten detent plug to 47.5 Nm (35 ft. lbs.).
24. Install shift tower onto the transmission case and tighten bolts to 9 Nm (7 ft. lbs.).