Assembly-Part 2
FRONT HOUSING1. Install mainshaft and countershaft bearings in front housing with hammer and driver.
2. Install mainshaft bearing retainer (1) and countershaft bearing retainers (2). Apply Mopar Lock & Seal Adhesive or equivalent to retainer bolts and tighten to 10 Nm (88 inch lbs.).
3. Install mainshaft (1) and countershaft (2) in build Fixture 9626 (3).
4. Install input shaft bearing (1) on mainshaft (2).
5. Install input shaft (1) on mainshaft (2).
6. Install 5-6 shift rail (1) and 3-4 shift rail (2) in build Fixture 9626. Then install 5-6 shift fork (3) and 3-4 shift fork (4)
WARNING: Use tongs when handling heated components. Failure to follow these instructions will result in personal injury.
CAUTION: A bearing heater (3) is used to heat Plug 9625 (1) and Plug 96191 (2). Use only a bearing heater/hot plate and follow manufacturer's instructions. Heat components to 100 - 177 Celsius (212° Minimum - 350° Maximum Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.
7. Heat Plug 9625 (1) and Plug 96191 (2) to a maximum of 177 Celsius (350° Fahrenheit) with bearing heater (3).
8. With tongs place heated Plug 9625 in countershaft bearing and heated Plug 96191 into mainshaft bearing. Allow plugs to heat bearings for two minutes.
9. Remove Plug 9625 and Plug 9619 with welding gloves or tongs, then install front housing (1) on mainshaft and countershaft in fixture (2).
10. Apply Mopar Lock & Seal Adhesive or equivalent to shift fork pivot bolts. Install 5-6 (1) and 3-4 (2) shift fork pivot bolts, in both sides of the front housing and tighten to 35 Nm (26 ft. lbs.).
NOTE: Verify shift fork pivot holes are aligned with pivot bolt holes before installing bolts.
11. Install two detents (1) in the side of the front housing (2).
FINAL ASSEMBLY
1. Turn front housing (1) with fixture (2) over onto the front housing and remove fixture.
2. Install intermediate plate (1) and two dowels (2).
3. Install intermediate plate (1) bolts (2) and tighten to 22 Nm (16 ft. lbs.).
4. Install interlock plate washers (1) on support (2).
5. Install interlock plate (2) and tighten bolts (1) to 10 Nm (88 inch lbs.).
6. Install second gear bearing (1) on mainshaft (2).
7. Install second gear (1) on mainshaft (2).
8. Install second gear inner friction ring (1) on second gear (2).
9. Install second gear outer friction ring (1) on second gear (2).
10. Install second gear bracket ring (1) on second gear (2).
11. Align 1-2 synchronizer hub (1) with bracket ring on mainshaft and install hub with Installer D389 (2).
NOTE: If 1-2 synchronizer hub is installed incorrectly the snap ring groove will not be visible.
12. Install 1-2 synchronizer hub (1) snap ring (2).
13. Install 1-2 synchronizer hub (1) detents (2).
14. Install 1-2 synchronizer sleeve (2) on 1-2 hub (1).
NOTE: Align grooves in the sleeve with detents in hub.
15. Install first gear bracket ring (1) on 1-2 hub (2).
16. Install first gear outer friction ring (1) on 1-2 hub (2).
17. Install first gear inner friction ring (1) on 1-2 hub (2).
18. Install first gear bearing (1) on mainshaft (2).
19. Install first gear (1) on mainshaft (2).
WARNING: Use welding gloves or tongs when handling heated components. Failure to follow these instructions will result in personal injury.
CAUTION: A bearing heater is used to heat reverse bearing race (1). Use only a bearing heater/hot plate and follow manufacturer's instructions. Heat components to 100-177 Celsius (212° Minimum - 350° Maximum Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.
20. Heat reverse bearing race (1) with bearing heater (2) to a maximum of 177 Celsius (350° Fahrenheit).
21. With welding gloves or tongs install reverse bearing race (1) on mainshaft (2).
22. Install reverse gear bearing (1) on bearing race (2).
23. Install reverse gear (1) on mainshaft (2).
24. Install reverse gear friction/blocker ring (1) on reverse gear (2).
25. Install reverse synchronizer detents (1) in reverse hub (2).
26. Install reverse synchronizer sleeve (1) on reverse hub (2).
NOTE: Align grooves in the sleeve with detents in hub.
27. Install reverse gear synchronizer hub (1) with Installer D389 (2).
28. Install main shift rail (1) bearings (2) on main shift rail.
29. Install main shift rail (1) through rail support (2) and housing, then rotate counterclockwise into place.
30. Install 1-2 shift fork then, install 1-2 shift rail (2) into shift fork and housing. Install shift fork roll pin (1).
31. Install reverse shift rail (1) into the housing. Then install reverse shift fork (2) and pull shift rail (1) up into the shift fork.
32. Install reverse shift fork roll pin (1).
WARNING: Use tongs when handling heated components. Failure to follow these instructions will result in personal injury.
CAUTION: A bearing heater (2) is used to heat Plug 96192 (1). Use only a bearing heater/hot plate and follow manufacturer's instructions. Heat components to 100 - 177 Celsius (212° Minimum - 350° Maximum Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.
33. Heat Plug 96192 (1) with bearing heater (2) to a maximum of 177 Celsius (350° Fahrenheit).
34. With tongs place Plug 96192 in rear housing mainshaft bearing (2). Allow plug to heat bearing for two minutes.
35. Apply a bead of Mopar Gasket Maker or equivalent to the front housing sealing surface.
36. Remove plug and install rear housing (1) on front housing (2).
37. Install housing bolts and tighten to 22 Nm (16 ft. lbs.).
38. Install output shaft seal in rear housing (1) with Installer 9629 (2).
39. Install 4x4 transmission output shaft nut with Socket 9584 and tighten to 200 Nm (147 ft. lbs.). Then loosen nut and tighten to 170 Nm (125 ft. lbs.).
40. Drive output shaft flange onto the output shaft with Installer D389.
41. Install 4x2 transmission output shaft flange (1) and tighten bolt (2) to 200 Nm (147 ft. lbs.). Then loosen bolt and tighten to 170 Nm (125 ft. lbs.). Remove Wrench 9586 from input shaft.
42. Install two detent plugs in the top of the rear housing.
43. Install large detent plunger (1) and spring (2) in the side of the rear housing.
44. Install large detent plug (1) in the side of the rear housing (2).
45. Install back up lamp switch (1) and tighten bolt (2) to 10 Nm (88 inch lbs.). Then lay transmission down on bench.
46. Install input shaft (1) snap ring (2).
47. Install input shaft seal in front housing with Installer 9620 (1) and Tube C3717 (2).
48. Install clutch bearing release support (1) and tighten bolts (2) to 10 Nm (88 inch lbs.).
49. Install Wrench 9586 (1) on input shaft (2).
50. Install countershaft bolt (1) in front housing. Tighten bolt (1) to 90 Nm (66 ft. lbs.).
51. Install countershaft plug in front housing (1) with Installer 9622 (2) and Handle C4171.
52. Install the cover plate for the second shift tower location, if necessary.
53. Apply Mopar Lock & Seal or equivalent to shifter socket threads and install shifter socket (1).