Part 2

36. Install third gear blocker ring (1) on stop ring (2).





37. Install 3-4 synchronizer hub (1) on third gear synchronizer rings (2).





38. Install third gear synchronizer hub (1) snap ring (2).





39. Install 3-4 synchronizer sleeve (3) on hub (2) and push sleeve to the bottom of the hub.

NOTE: 3-4 synchronizer sleeve (3) and hub (2) have one small tooth. They must be aligned to install synchronizer sleeve (3).

40. Install 3-4 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents (1) behind synchronizer sleeve (3).





41. Install fourth gear blocker ring (1) on synchronizer hub (2).





42. Install fourth gear outer friction ring (1) on synchronizer hub (2).





43. Install fourth gear inner friction ring (1) on synchronizer hub (2).





44. Install fourth gear stop ring (1) with teeth pointing down on synchronizer hub (2).
45. Hold fourth gear stop ring (1) on synchronizer hub (2) and center 3-4 synchronizer sleeve on hub.





46. Install fourth gear (1) and bearing (2).





47. Heat fourth gear thrust washer (1) on bearing heater (2) to a maximum of 150 Celsius (300° Fahrenheit).





48. Using welding gloves or tongs, install fourth gear (1) thrust washer (2).





49. Install fourth gear (1) snap ring (2).





50. Install sixth gear (1) and bearing (2) on mainshaft (3).





51. Install sixth gear stop ring (1) on sixth gear (2).





52. Install sixth gear friction ring (1) on stop ring (2).





53. Install 5-6 synchronizer hub (1) on sixth gear synchronizer rings (2).





54. Heat mainshaft bearing (1) on bearing heater to a maximum of 150 Celsius (300° Fahrenheit).





55. Using welding gloves or tongs, install mainshaft bearing (1) on mainshaft.
56. Install mainshaft bearing (1) snap ring (2).





57. Install 5-6 synchronizer sleeve (1) on hub (2) and push sleeve to the bottom of the hub.





58. Install 5-6 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind synchronizer sleeve (3).





59. Install fifth gear friction ring (1) onto hub (2).





60. Install fifth gear blocker ring with teeth pointing down (1) onto hub (2).
61. Hold fifth gear blocker ring (1) onto hub (2) and center 5-6 synchronizer sleeve on hub (2).

REAR HOUSING





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





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





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





5. Install idler gear (1) with taller thrust face up into rear housing (2) and 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.

NOTE: The transmission may or not be equipped with the oil slinger. Service replacement parts will come with an oil slinger. It is not necessary to remove the oil slinger if the original part was not equipped with an oil slinger.





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





11. Install reverse idler gear shaft bolt (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, end-play measurements must taken to ensure proper bearing preload. Failure to follow these instructions will result in bearing damage.

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





7. Apply Mopar(TM) 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 pin bolts (1) into housing and tighten to 58 Nm (43 ft. lbs.).





11. Remove shift rail (2) tie strap.





12. On a 4x2 transmission shift two shift rails to lock the transmission in two gears. Then install flange (1) on output shaft (2) and tighten bolt to 260 Nm (190 ft. lbs.). Return shift rails to neutral position.





13. Push shift tower boot (1) onto shift tower (2).





14. Apply Mopar(TM) Gasket Maker to the shift tower opening.
15. Install shift tower (2) and tighten bolts (1) to 23 Nm (17 ft. lbs.).





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