Part 1 of 2
ASSEMBLYNOTE: Sealers are used at all case joints. Use Mopar Gasket Maker or equivalent for all case joints and Mopar silicone sealer or equivalent for the input shaft bearing retainer.
SYNCHRONIZER
1. Slide sleeve onto the hub, leaving enough room to install the spring in the hub and strut in the hub groove.
2. Install first spring in the hub, then install a strut over the spring. Verify spring is seated in the spring bore in the strut.
3. Slide sleeve onto the hub far enough to hold the first strut and spring in place.
4. Place detent ball in the top of the strut, then press the ball into place with a small screwdriver. Work the sleeve over the ball to hold it in place.
5. Repeat procedure for the remaining springs, struts and balls. Use tape or rubber bands to temporarily secure each strut and ball as they are installed.
6. Verify the synchro three springs, struts and detent balls are all in place (Fig. 49).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears, bearings and immerse each synchro ring with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.
1. Install reverse gear needle bearing up against shoulder on output shaft (Fig. 50).
2. Install reverse gear over needle bearing (Fig. 51).
3. Install brass synchro ring on reverse gear (Fig. 52).
4. Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Remover 6310-1 (Fig. 53).
CAUTION: One side of the hub has shoulders around the hub bore, this side faces the front of the shaft. One side of the sleeve is tapered the tapered side faces the front of the shaft.
5. Install new fifth-reverse hub snap ring (Fig. 54). Verify snap ring is seated in the groove.
6. Install fifth gear synchro ring in synchro hub and sleeve (Fig. 55).
7. Install fifth gear bearing. Spread bearing only enough to clear shoulder on output shaft (Fig. 56). Verify bearing is properly seated.
8. Install fifth gear on shaft and onto bearing (Fig. 57).
9. Invert output shaft and set the shaft in Collar 6310-1 so fifth gear is seated on the tool (Fig. 58).
10. Install first gear bearing on output shaft (Fig. 58). Verify bearing is seated on shaft shoulder and is properly joined.
11. Install first gear on shaft and over bearing (Fig. 59) with bearing synchro cone facing up.
12. Install first gear synchro ring (Fig. 60).
13. Start 1-2 synchro assembly on shaft by hand (Fig. 61).
CAUTION: One side of the synchro sleeve is marked First Gear Side, this side must face first gear.
14. Press 1-2 synchro onto output shaft using suitable size pipe and shop press (Fig. 62).
CAUTION: Keep synchro ring and sleeve aligned as the hub is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.
15. Install interm ring.
16. Install new 1-2 synchro hub snap ring (Fig. 63). Verify snap ring is seated in shaft groove.
17. Install second gear synchro ring in 1-2 synchro hub and sleeve (Fig. 64). Verify synchro ring is seated in sleeve.
18. Install synchro friction cone and synchro cone in synchro ring.
19. Install second gear needle bearing on shaft (Fig. 65).
20. Install second gear onto shaft and bearing (Fig. 66). Verify second gear is seated on synchro components.
21. Install two-piece thrust washer with halves seated in the shaft groove and washer lugs seated in shaft lug bores (Fig. 67). Verify i.d. grooves and markings noted during removal are facing the correct direction.
22. Start retaining ring around two-piece thrust washer (Fig. 68). Verify locating dimple is between thrust washer halves.
23. Seat thrust washer retaining ring with plastic mallet (Fig. 69).
24. Install third gear needle bearing on shaft (Fig. 70).
25. Install third gear on shaft and bearing (Fig. 71).
26. Install third speed synchro ring on third gear (Fig. 72).
27. Start 3-4 synchro hub on output shaft splines by hand (Fig. 73).
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards if care is not exercised. One side of the sleeve has grooves in it, this side must faces the front of the shaft.
28. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe (Fig. 74).
NOTE: Tool presses on hub must be as close to output shaft as possible but not contacting the shaft splines.
29. Install new 3-4 synchro hub snap ring (Fig. 75). Verify snap ring is seated in groove.
30. Install output shaft bearing.
31. Install output shaft bearing snap ring with heavy duty snap ring pliers (Fig. 76). Verify snap ring is seated in shaft groove.
NOTE: Spread snap ring only enough to install it.
32. Verify position of synchro sleeves before proceeding (Fig. 77). Grooved side of 3-4 sleeve must face forward. First gear side of 1-2 sleeve must face first gear. Tapered side of fifth-reverse sleeve must face forward.
REVERSE IDLER ASSEMBLY
1. Lubricate idler components with gear lube.
2. Slide idler gear bearing on shaft (Fig. 78). Bearing fits either way on shaft.
3. Slide gear onto shaft. Side of gear with recess goes to rear (Fig. 78).
4. Place first lock ball in dimple at rear end of idler shaft (Fig. 78). Petroleum jelly can be used to hold ball in place if desired.
5. Slide thrust rear thrust washer onto shaft and over lock ball (Fig. 79).
6. Install snap ring in groove at rear of shaft (Fig. 79).
7. Install lock ball in dimple at front of shaft. Hold ball in place with petroleum jelly if desired.
8. Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 80).
9. Install wave washer, flat washer and remaining snap ring on idler shaft (Fig. 80). Verify snap ring is seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS
1. Inspect shift shaft bushing and bearing for damage.
2. If necessary, the shift shaft bushing can be replaced as follows:
a. Locate a bolt that will thread into the bushing without great effort.
b. Thread the bolt into the bushing, allowing the bolt to make its own threads in the bushing.
c. Attach a slide hammer or suitable puller to the bolt and remove bushing.
d. Use the short end of Installer 8119 to install the new bushing.
e. Bushing is correctly installed if flush with the transmission case.
3. If necessary, the shift shaft bearing can be replaced as follows:
a. Locate a bolt that will thread into the bearing without great effort.
b. Thread the bolt into the bearing as much as possible.
c. Attach a slide hammer or suitable puller to the bolt and remove the bearing.
d. Use the short end of Installer 8119 to install the new bearing.
e. Bearing is correctly installed if flush with the transmission case.
4. Inspect detent plunger bushings for damage.
NOTE: The detent plunger bushings are installed to a specific depth. The space between the two bushings when correctly installed contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted.
5. If necessary, the detent plunger bushings can be replaced as follows:
a. Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore.
b. Remove the bushings from the shift shaft bore.
c. Install a new detent plunger bushing on the long end of Installer 8118.
d. Start bushing in the detent plunger bore in the case.
e. Drive bushing into the bore until the tool contacts the transmission case.
f. Install a new detent plunger bushing on the short end of Installer 8118.
g. Start the bushing in the detent plunger bore in the case.
h. Drive bushing into the bore until the tool contacts the transmission case.
GEARTRAIN ASSEMBLY
1. Install Adapter 6747-1A on input shaft hub of Fixture 6747 (Fig. 81). Then install Adapter 6747-2A on front bearing hub of countershaft. Be sure the shoulder is seated against the countershaft.
2. Install input shaft in fixture tool with Adapter Tool 6747-1A positioned under the shaft as shown (Fig. 82).
3. Install pilot bearing in input shaft (Fig. 82).
NOTE: The side of the pilot bearing with the small diameter goes toward the input shaft.
4. Install fourth gear synchro ring on input shaft (Fig. 83).
5. Adjust height of idler gear pedestal on fixture (Fig. 84). Start with a basic height of 18.4 cm (7-1/4 inch). Final adjustment can be made after gear is positioned on pedestal.
6. Install assembled output shaft and geartrain in input shaft (Fig. 85). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
7. Install Adapter 6747-2A on front bearing hub of countershaft, if not previously done. The shoulder goes toward the countershaft.
8. Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears before proceeding (Fig. 86).
9. Check alignment of countershaft and output shaft gear teeth. Gears may not align perfectly a difference in height of 1.57 to 3.18 mm (1/16 to 1/8 inch) will probably exist. This will not interfere with assembly. If difference is greater than this, the countershaft adapter tool is probably upside down.
10. Position reverse idler in support cup of fixture (Fig. 87). Verify idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out from the geartrain. Adjust pedestal up or down if necessary and verify short end of idler shaft is facing up as shown.
11. On 2-wheel drive transmission, thread one Alignment Pin 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear as shown (Fig. 88).
12. Assemble 1-2 and fifth reverse-shift forks (Fig. 89). Arm of fifth-reverse fork goes through slot in 1-2 fork.
13. Install assembled shift forks in synchro sleeves and verify forks are seated in sleeves (Fig. 90).