Part 2

ASSEMBLY

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Install the front output shaft (2) into the front output shaft front bearing.










2. Install the front output shaft bearing inner snap-ring (2) onto the output shaft.
3. Install the new front output shaft seal with Seal Installer MB991168A.










4. Insert front drive sprocket (3) in drive chain (2).
5. Install drive chain around rear drive sprocket.
6. Position rear drive sprocket over the output shaft and lower the sprocket and chain assembly until the front sprocket is positioned over the front output shaft.
7. Align the splines in the sprockets to the splines on the output shafts and install the sprockets onto the output shafts.










8. Install front sprocket (2) retaining ring (3).










9. Install rear sprocket (2) retaining ring (3).










10. Insert magnet (1) in front case pocket (2).

REAR CASE










1. Install the oil pick-up tube and screen into the rear case half.
2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
3. Align mainshaft with the rear output shaft bearing and align shift rail with bore in rear case. Then install rear case (2). Verify that the case alignment dowels correctly seat into their mating recesses.










4. Install 4-5 rear case (2) to front case (1) bolts (3) to hold rear case in position. Tighten bolts snug but not to specified torque at this time.

CAUTION: Verify that shift rail, and case alignment dowels are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.

5. Tighten bolts to 27-34 Nm (20-25 ft. lbs.).










6. Install rear output bearing inner snap-ring (3) to output shaft (1).

OIL PUMP AND REAR EXTENSION










1. Install the oil pump (3) onto the output shaft (2).










2. Engage the oil pump pick-up tube (2) into the oil pump (1). Verify that the pick-up tube o-ring is on the tube and is correctly installed to the oil pump.










3. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear extension housing. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into output bearing.
4. Install extension housing (2) onto the rear case half (1).










5. Install rear extension bolts (2). Tighten the bolts to 27-34 Nm (20-25 ft.lbs.).










6. Install the extension housing dust boot and seal assembly with Seal Installer 9037 (3) and Universal Handle C-4171 (2).










7. Install the front companion flange onto the front output shaft.
8. Install two bolts 180° apart into the front output shaft companion flange.
9. Place holder (1) over the bolts (2) and against the companion flange.
10. Install a new front companion flange nut. Tighten the companion flange nut to 176-271 Nm (130-200 ft.lbs.).