Assembly

MANUAL TRANSMISSION - T56

ASSEMBLY
TRANSMISSION ADAPTER





1. Install shift rail bushings (2) with Installer 9368 (3) and Handle C4171 (1).
2. Install input shaft seal with Installer 9366.





3. Install countershaft and mainshaft select shims (1) in bearing cup bores (2).





4. Install countershaft and mainshaft bearing cups (2) into adapter plate (2).

TRANSMISSION CASE
1. Install shift rail bushings with Installer 9368 and Handle C4171.





2. Install mainshaft bearing cup with Installer 9373 (2) and Handle C4171 (1).





3. Install countershaft bearing cup with Installer 9373 (2) and Handle C4171 (1).

EXTENSION HOUSING





1. Install countershaft bearing (1) with Installer 9394 (2) and Handle C4171 (3).





2. Install mainshaft roller bearing race (1) with Installer 9392 (2) and Handle C4171 (3).
3. Install mainshaft roller bearing race snap ring.
4. Install shift rail bushings with Installer 9368 and Handle C4171.
5. Install reverse idler gear shaft.





6. Install thrust washer, reverse idler gear (3) and bearing (2).





7. Install idler gear bracket into the tail housing (1). Install bolts (2) with Loctite 242 and tighten to 24 Nm (18 ft. lbs.).

INPUT SHAFT





1. Install input shaft bearing cup with Installer 9380 (1) and Handle C4171 (2).





2. Install input shaft bearing (3) with Installer 6052 (2) and Tube MB991317 (1).

COUNTERSHAFT





1. Install countershaft (3) bearings (2) with Installer MB998909 (1) and a press.

MAINSHAFT

CAUTION: Mainshaft snap rings are not interchangeable.





1. Install mainshaft (3) tapered bearing (2) with Installer 9377 (1) and a press.





2. Install third gear bearing (2) and spacer (1) on mainshaft.





3. Press third gear (1) and 3-4 synchronizer hub (2) onto the mainshaft with Splitter 9375.





4. Install 3-4 synchronizer sleeve.
5. Install 3-4 synchronizer (1) original or new snap ring (2).





6. Press second gear (1) and 1-2 synchronizer hub (2) onto mainshaft with Splitter 9375.





7. Install 1-2 thrust washer and bracket ring (1) assembly onto 1-2 synchronizer (2).





8. Install original or new 1-2 synchronizer (1) snap ring (2) on mainshaft.





9. Install first gear (1) and bearing (2) on mainshaft.





10. Install rear mainshaft tapered bearing (1) on top of first gear (2).

TRANSMISSION HOUSING

1. Install input shaft seal into adapter plate with Installer 9366.





2. Install input shaft (2) into adapter plate (3).





3. Install countershaft (1) assembly into adapter.





4. Tilt countershaft (4) sideways then install mainshaft (1) and shift rail (2) assemblies into adapter (3).





5. Install reverse rail assembly (2) into adapter (3) and on mainshaft (1).
6. Install guide plate and tighten torx bolts to 22 Nm (16 ft. lbs.).
7. Apply Mopar Gasket Maker to adapter sealing surface.





8. Install transmission case (1) on gear set until shift rail through the guide plate. Then install offset lever spring, ball and lever on shift rail and seat transmission case on adapter (2).





9. Install front adapter (2) bolts (3) and tighten to 34 Nm (25 ft. lbs.).





10. Install two torx screws (2) on top of transmission case (1).





11. Drive roll pin down into offset lever (3) with hammer (2) and punch (1).





12. Apply Loctite 242 to shift detente (1) threads. Install shift detente assembly with new O-ring and tighten to 34 Nm (25 ft. lbs.).
13. Install reverse lockout solenoid.
14. Apply Mopar Gasket Maker to top plate sealing surface.
15. Install top plate bolts and tighten to 20 Nm (15 ft. lbs.).





16. Install sixth gear bearing and gear (1) on countershaft (2).





17. Install sixth gear stop ring (1).





18. Install 5-6 synchronizer (1) on countershaft (2).
19. Install 5-6 synchronizer snap ring.





20. Install 5-6 shift fork (1) and synchronizer sleeve (2).





21. Install new 5-6 gear shift fork (1) snap ring (2).





22. Install 5-6 gear (2) on mainshaft with Installer 9391(1).
23. Install fifth gear stop ring.





24. Install fifth gear bearing and gear (1) on countershaft (2).





25. Install fifth gear (1) thrust washer (2).





26. Install new fifth gear (1) snap ring (2).





27. Install reverse shift fork (1) and synchronizer (2) sleeve onto main shaft.





28. Install reverse gear (3) on countershaft with Installer 9391 (2) bolt, bearing and washer and 1 3/16 half inch drive socket (1).
29. Install reverse gear snap ring on countershaft.





30. Install reverse synchronizer (1) snap ring (2).





31. Install new reverse shift fork (1) snap ring (2) with the flat side facing rearward.





32. Install reverse gear (3), bearing (5), wave washer (2) and brass bracket ring (1) on mainshaft (4).





33. Install reverse gear (1) thrust washer (2) and snap ring (4).





34. Install mainshaft (3) roller bearing (4), spacers (2) and snap ring.
35. Apply Mopar Gasket Maker to tail housing sealing surface.





36. Install the six tail housing (1) to case bolts (2) and tighten bolts to 41 Nm (30 ft. lbs.).





37. Install two tail housing nuts (2) on top of transmission tail housing (3).





38. Slide offset lever (1) onto shaft in tail housing (2).





39. Install offset lever (3) roll pin with hammer (1) and punch (2).
40. Install Mopar Gasket Maker to the shift cover sealing surface and position cover on the transmission.
41. Install shift cover four mounting bolts and tighten to 18 Nm (13 ft. lbs.).