Part 1

ASSEMBLY

Special Tools:










TRANSMISSION ADAPTER





NOTE: Refer to Adjustments for Mainshaft and Countershaft end play shim selection.

1. Install countershaft select shims and bearing cup (1) into adapter plate. Install mainshaft select shims and bearing cup (2) into adapter plate.





2. Install shift rail bearing with Handle (1) and Installer (2).





3. Install shift rail bushing with Installer (1).





4. Install input shaft seal with Handle (1) and Installer (2).

TRANSMISSION CASE





1. Install shift rail bearing with Handle (1) and Installer (2).





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





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

EXTENSION HOUSING





1. Install countershaft bearing (1) with Installer (2) and Handle (3) then install snap ring.





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





3. Install mainshaft bearing cup (2) snap ring (1).





4. Install reverse idler gear shaft in extension housing (1).
5. Install reverse idler gear bearing (2) and idler gear (3).





6. Install idler gear bracket into the tail housing (1).
7. Apply Mopar (R) Lock AND Seal Adhesive or equivalent on idler gear bracket bolts (2). Install bolts (2) and tighten to 30 Nm (22 ft. lbs.).





8. Install shift rail bushings (1) with Installer (2).

INPUT SHAFT





WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max 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.






1. Heat input shaft bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install bearing (1) on input shaft (2) with tongs or welding gloves.





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

COUNTERSHAFT





WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max 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.






1. Heat countershaft (1) bearings (2) to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Install countershaft (1) bearings (2) on shaft with tongs or welding gloves.

MAINSHAFT





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





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





3. Install third gear (1) on mainshaft (2).





4. Install third gear synchronizer rings (1) on third gear (2).





5. Install 3-4 synchronizer hub (1) on mainshaft (2).

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






6. Install 3-4 synchronizer hub (1) snap ring (2) on mainshaft.





7. Install synchronizer detents (1) in 3-4 synchronizer hub (2).

NOTE: 1-2 and 3-4 synchronizer detents are the same.






8. Install 3-4 synchronizer sleeve (1) on 3-4 synchronizer hub (2).






WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max 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.

9. Heat mainshaft transmission adapter bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install on mainshaft with tongs or welding gloves.





10. Install second gear bearing (1) on mainshaft (2).





11. Install second gear bearing spacer (1) on mainshaft (2).





12. Install second gear (1) on mainshaft (2).





13. Install second gear synchronizer rings (1) on second gear (2).





14. Install 1-2 synchronizer hub (1) on mainshaft (2).

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






15. Install 1-2 synchronizer hub sleeve (1) and detents (2).

NOTE: 1-2 and 3-4 synchronizer detents are the same.






16. Install 1-2 synchronizer hub split rings (1) on mainshaft (2).





17. Install 1-2 synchronizer hub split rings retainer (1) on split rings (2).





18. Install first gear synchronizer rings (1) on 1-2 synchronizer hub (2).





19. Install first gear bearing (1) on mainshaft (2).





20. Install first gear (1) on mainshaft (2).

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







WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max 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.

21. Heat mainshaft case bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install on mainshaft with tongs or welding gloves.





22. Position sixth gear (1) on mainshaft (2).
23. Install sixth gear on mainshaft with Installer and Coupler.