Part 2

ASSEMBLY (Continued)


TRANSMISSION HOUSING





1. Install input shaft (2) into transmission adapter plate. Install fourth gear synchronizer rings (1) onto fourth gear.





2. Install countershaft (1) assembly into transmission adapter.





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





4. Install countershaft thrust washer (1) on countershaft (2).





5. Install reverse rail assembly (2) into transmission adapter (3).





6. Apply Mopar (R) ATF-RTV to transmission adapter (2) sealing surface.
7. Install transmission case (1) on gear set until shift rail passes through case bushing. Then install skip shift lever on shift rail and seat transmission case on adapter (2).





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





9. Apply Mopar (R) Lock AND Seal Adhesive to shift lever guide bolts. Install guide bolts (2) in transmission case (1) and tighten to 27 Nm (20 ft. lbs.).





10. Install roller detent (1) and spring (2) into transmission adapter.





11. Apply Mopar (R) Lock AND Seal to roller detent bolt threads. Install bolt (1) into transmission adapter (2) and tighten to 40 Nm (30 ft. lbs.).





12. Install skip shift solenoid (1) into side of case (2) and tighten to 34 Nm (25 ft. lbs.).





13. Install skip shift lever (1) roll pin (2) with a hammer and punch.





14. Install side shift detent (1) into case (2) and tighten to 40 Nm (30 ft. lbs.).





15. Apply Mopar (R) ATF-RTV to top cover sealing surface.
16. Install top cover (1) on case (2) and tighten bolts to 20 Nm (15 ft. lbs.).





17. Install sixth gear bearing spacer (1) on countershaft (2).





18. Install sixth gear bearing (1) on countershaft (2).





19. Install sixth gear (1) on countershaft (2).





20. Install sixth gear synchronizer rings (1) on countershaft sixth gear (2).





21. Install 5-6 synchronizer hub (2) on countershaft with Installer (1).

CAUTION: Synchronizer rings must be aligned with synchronizer hub and sixth gear during installation. Failure to follow these instructions will result in damage to the synchronizer rings.






22. Install 5-6 synchronizer hub (1) snap ring (2).





23. Install 5-6 synchronizer shift fork (1) synchronizer sleeve (2) and hub detents (3).

NOTE: 5-6 and reverse synchronizer detents are the same.






24. Install 5-6 synchronizer hub snap ring (1).
25. Install new 5-6 gear shift fork snap ring.





26. Install fifth gear (1) on mainshaft with Installer (2) and Coupler.





27. Install fifth gear split rings (1) on mainshaft (2).





28. Install fifth gear split rings retainer (1) on mainshaft (2).





29. Install fifth gear synchronizer rings (1) on 5-6 synchronizer hub (2).





30. Install fifth gear bearing spacer (1) on countershaft (2).





31. Install fifth gear bearing (1) on countershaft (2).





32. Install fifth gear (1) on countershaft (2). CAUTION: Synchronizer rings must be aligned with synchronizer hub and fifth gear during installation. Failure to follow these instructions will result in damage to the synchronizer rings.






33. Install fifth gear thrust washer (2) and snap ring (1) on countershaft.





34. Install reverse gear (1) on countershaft with Installer (2).





35. Install reverse gear (1) snap ring (2) on countershaft.





36. Install reverse shift fork (1) synchronizer hub with detents (2) and sleeve.

NOTE: 5-6 and reverse synchronizer detents are the same.






37. Install reverse synchronizer hub (1) snap ring (2).





38. Install new reverse shift fork (1) snap ring (2).





39. Install reverse synchronizer rings (1) on reverse synchronizer hub.





40. Install reverse gear bearing (1) on mainshaft.





41. Install reverse gear (1) on mainshaft (2).

CAUTION: Synchronizer rings must be aligned with synchronizer hub and reverse gear during installation. Failure to follow these instructions will result in damage to the synchronizer rings.






42. Install reverse gear (1) thrust washer (2) on mainshaft.





43. Install reverse gear (1) snap ring (2) on mainshaft.





44. Install mainshaft roller bearing (1) and spacers (2) on mainshaft.





45. Install mainshaft roller bearing (1) snap ring (2).





46. Apply Mopar (R) ATF-RTV to extension housing sealing surface.
47. Install extension housing (1) on transmission case (2).





48. Install extension housing (1) bolts (2) and tighten bolts to 48 Nm (35 ft. lbs.).





49. Install extension housing (1) nuts (2) and tighten bolts to 48 Nm (35 ft. lbs.).





50. Install offset lever (1) on shift rail (2).





51. Install offset lever (1) roll pin (2) with a hammer and punch.





52. Install Mopar (R) ATF-RTV to the shift cover sealing surface.
53. Install shift cover (1) bolts (2) and tighten to 20 Nm (15 ft. lbs.).





54. Install output shaft seal in extension housing (1) with Installer (2).





55. Install the output flange to the transmission output shaft.
56. Hold the output flange (3) with Special Tool (2) Flange Wrench and tighten the output flange locknut to 200 Nm (148 ft. lbs.).