Assembly-Part 2

REAR HOUSING





1. Install countershaft bearing cup with Installer 9589 (1) and Handle C4171 (2).





2. Install mainshaft bearing cup with Installer 9588 (1) and Handle C4171 (2).
3. Install output shaft seal with Installer 9598.





4. Install reverse idler bearing (1) into idler gear (2).





5. Install idler gear (1) into rear housing (2) off to the side. For mainshaft/countershaft installation clearance.





6. Tie strap (2) shift rails (1) together.





7. Install reverse (1), 1-2 (2) and 3-4 (3) shift rails and forks as and assembly on synchronizer sleeves.





8. Install mainshaft with shift rails (2) into the rear housing. Tilt the mainshaft then tilt the countershaft (1) into the housing.





9. Position first/reverse oil slinger (1) between the mainshaft first (2) and reverse gears, then straighten the shafts in the housing.

CAUTION: Oil slinger is fragile and can crack during installation. Failure to follow these instructions will result in cracking the oil slinger and lack of oil to first/reverse bearing.





10. Position reverse idler gear and install idler shaft (2) with bolt (1).





11. Install reverse idler gear shaft pin (1) into rear housing (2) and tighten to 58 Nm (43 ft. lbs.).





12. Install 5-6 shift shoe narrow ends (1) into the 5-6 synchronizer sleeves (2).





13. Install 5-6 shift fork (1) into the shift rail.

FRONT HOUSING

CAUTION: If mainshaft/bearings or countershaft/ bearings are replaced endplay measurements, must taken to ensure proper bearing preload. Failure to follow these instruction will result in bearing damage.





1. Install input shaft seal front housing bore (1) with Installer 9595 (2).





2. Install input shaft retainer (1) and tighten bolts (2) to 23 Nm (17 ft. lbs.).





3. Install select end play shims into the countershaft bearing cup bore.





4. Install countershaft bearing cup with Installer 9589 (1) and Handle C4171 (2).





5. Install input shaft bearing oil supply washer and select end play shims into mainshaft bearing cup bore.
6. Install mainshaft bearing cup with Installer 9588 (1) and Handle C4171 (2).
7. Apply Mopar Gasket Maker to the rear housing sealing surface.
8. Install front housing (1) onto the rear housing (2).
9. Install housing bolts and tighten to 58 Nm (43 ft. lbs.).





10. Install 5-6 shift fork pins (1) into housing and tighten to 58 Nm (43 ft. lbs.).





11. Push shift tower boot (1) onto shift tower (2).
12. Remove shift fork tie strap.
13. Apply Mopar Gasket Maker to the shift tower opening.





14. Install shift tower (2) and tighten bolts (1) to 23 Nm (17 ft. lbs.).





15. Install back up lamp switch (1) and bolt (2).