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Disassembly And Assembly

DISASSEMBLY

CAUTION:

If any of the shift cables or shift cable brackets are removed, the cable adjustment must be checked. This adjustment is critical. If not set correctly, transmission damage is possible.

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Place an oil drain pan under the drain plug and drain transmission fluid through the drain plug. Make sure the transmission is in the neutral position.

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NOTE:
Do not re-use the seal, install a new seal if removal is necessary.

NOTE:
Do not damage the case surface.
Using a suitable tool, remove and discard the oil seal (1).

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Using a suitable tool, carefully open the stakes (1) on the lock nut. Remove the output shaft lock nut using the input shaft holding tool from (special tool #2051600210, Socket, Spline Input Shaft 21 Teeth) and the output shaft locknut socket (special tool #2051500210, Socket, Output Shaft 60 mm).

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Remove the range position switch. Refer to SWITCH, RANGE POSITION, REMOVAL AND INSTALLATION .
Remove the output shaft lock nut (1) and the rear output bearing (2). Discard the output shaft lock nut.

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Stand the transmission on the bell housing end. Remove the rear shift fork detent plugs (1) with the balls and springs from the case.

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Remove the shift fork detent springs and shift fork detent balls from the front and rear case.
NOTE:
The shift fork detent spring and sleeve (1) go to the very front, right side detent. The remaining shift fork detent springs and shift fork detent balls (2) are all the same size and all the springs have the same tension.

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Remove the rear shift fork support bolts (1) from the left side of the transmission.

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Remove the rear shift fork support bolts (1) from the right side of the transmission.

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Remove the rear case bolts (1).

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Remove the rear case.
NOTE:
If necessary, lightly tap the rear case (1) with a soft-faced hammer in the vicinity of the mating surface to separate it from the front case.

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Remove the shim (2) from the mainshaft output shaft. If necessary, remove the mainshaft output shaft bearing (1).
NOTE:
Use a press and bearing splitter to remove the mainshaft output shaft bearing from the output shaft, if replacement is necessary.

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Remove the 3-4 shift fork (1) and the 5-6 (2) shift fork.

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NOTE:
When removing the output shaft, the needle bearing may stay inside (as shown in the illustration) of the mainshaft output shaft (1).
Remove the mainshaft output shaft (1) from the mainshaft.

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Remove the input shaft rear bearing (1).

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Remove the plastic oil feed tubes (1) from the case.

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Remove the oil separator bolts (1).

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Remove the shift guide plate bolts (1). Remove the shift guide plate (2).

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NOTE:
If necessary, lightly pry around the selector lever cover with a suitable screw driver or pry bar in the vicinity of the mating surface to separate the selector lever cover assembly from the case.
Remove the selector lever cover assembly bolts (1).

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Remove the selector lever cover assembly (1).

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Remove the inner shift lever bolt (1). Discard the inner shift lever bolt.

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Remove the outer shift lever (1).

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Remove the inner shift lever (1).

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Remove the front shift fork detent plugs (1) with the balls and springs. Discard the front shift fork detent plugs.

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Remove the right side front shift fork pivot bolt (2). Discard the right side front shift fork pivot bolt.

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Remove the left side front shift fork pivot bolt (2). Discard the left side front shift fork pivot bolt.

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Remove the reverse idler gear side bolt (1).

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Remove the reverse idler gear front bolt (1).

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Remove the countershaft bearing snap ring service plug using (special tool #2051400210, Socket, Allen 27 mm) (1).

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Remove the front input shield bolts (1) and remove the front input shield (2).

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Place the transmission assembly horizontally on the bench. Expand the countershaft snap ring (1) using a suitable pair of snap ring pliers and pull countershaft slightly to the rear to move snap ring from the groove.

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NOTE:
Illustration shown without mainshaft installed for clarity.
Expand the mainshaft snap ring (1) and pull mainshaft slightly to the rear to move the mainshaft snap ring from the groove in the bearing.

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NOTE:
Hold the mainshaft and countershaft while pulling rearward to keep the snap rings from re-engaging.
Remove the mainshaft and countershaft subassembly from the case.

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Remove the shift select shaft (1).
Remove the 1-2 shift fork (2).

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Remove the reverse shift fork and shaft (1).

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Remove the reverse idler gear (1).

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Remove the oil slinger (1) from the front case.

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Remove the front seal (1).
Remove the front input shaft seal from the case using (special tool #2051800210, Remover, Seal Input Shaft).

ASSEMBLY

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Thoroughly clean the case, the case mating surfaces and control cover using parts cleaner or equivalent, then fine scuff the pads.

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Install the front case seal into the groove. Verify the seal is seated in the channel.

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Install the oil slinger (1) in the case bore using petroleum jelly or transmission assembly lube to hold it in place on the case half. Verify the notches (2) are seated in the relief in the bore.

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Lay the countershaft (2) in the oil separator (1) so it protrudes from the case enough to build the assembly before sliding it in place.

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Loosely install the reverse shift fork and shift rail (1) into the transmission case. Verify the shift fork is seated in the groove of the sleeve in the correct orientation.

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Loosely install the mainshaft (1) on top of the countershaft.

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Install the reverse idler gear loosely in the case (1).

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Verify that the reverse idler gear (1) is installed prior to installing the 1-2 shift fork (2). Install the 1-2 shift fork (2) with the shoes oriented in the groove of the sleeve. There should be clearance in the slot on the oil separator (3) for free movement of the shift fork.

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Install the shift select shaft (1).

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Make sure the tabs (1) are seated correctly for the 1-2 shift fork.

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Align the shaft bearings (1) to the bores.

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With the transmission laying on the bench, gently start locating the shafts into the case bores until the bearings are located in their respective bores and pulled up to the snap rings.
NOTE:
Verify the shift shaft and shift forks remain aligned while sliding the countershaft and mainshaft into the case bores.

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Open the countershaft snap ring (1) using a suitable pair of snap ring pliers. Gently slide the countershaft into the snap ring until the snap ring aligns with the groove on the bearing.

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NOTE:
Illustration shown without mainshaft installed for clarity.
Stand the transmission vertically on the bell-housing end while supporting the shafts. Using a suitable pair of snap ring pliers, open the mainshaft snap ring (1) and seat the bearing in the bore with the snap ring in the groove on the bearing.

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Install the NEW front left side shift fork pivot bolt (2).

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Install the NEW right side front shift fork pivot bolt (2) and torque both shift fork pivot bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the reverse idler gear front bolt (1) with a NEW washer and hand tighten.

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Install the reverse idler gear side bolt (1) with a NEW washer and tighten both reverse idler bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the front shift fork detent balls, springs and NEW plugs into the top 2 bores (case standing on bell housing). Install the long sleeve and spring to the bottom front bore with the NEW plug and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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The shift fork detent spring and sleeve (1) go to the very front, right side detent. The remaining shift fork detent springs and shift fork detent balls (2) are all the same size and all the springs have the same tension.

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Install the inner shift lever (1).

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Install the outer shift lever (1).

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Install the NEW inner shift lever bolt (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Clean the selector lever cover assembly (1) and the mating surface on the case using a plastic scraper and brake clean. Apply a 1/8 inch bead of Mopar® orange RTV to the sealing surface of the selector lever cover assembly (1).

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Position the select lever cover assembly to the transmission, then install the five bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the shift guide plate (2). Install the shift guide plate bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the oil separator bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the plastic oil feed tubes (1).

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Verify the tubes are seated in the oil feed locating tip (1) and holes (2) in the front case half.

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Verify the oil feed tube is seated in the upper guide holes (2).

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Install the 3-4 shift fork (1) and the 5-6 shift fork (2) on the mainshaft.

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Install the input shaft rear bearing (1).

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If replacing the mainshaft output shaft bearing, press the NEW mainshaft output shaft bearing (2) on the mainshaft output shaft (3) using (special tool #2052300210, Installer, Bearing Output Shaft) (1).

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Install the mainshaft output shaft to the mainshaft. Make sure the synchronizer (1) is fully seated.

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Install the output shim (2) to the mainshaft output shaft.

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Install the seal (1) into the rear case half. Verify the seal (1) is fully seated in the groove.

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Clean both case half mating surfaces. Apply a 1/8 inch bead of Mopar® orange RTV around the stationary case half mating surface. Operate the selector lever and shift into 2nd gear. Install the rear case (1).
NOTE:
Before installing the rear case, verify the shift select shaft and reverse fork shaft are standing vertical. In addition, verify that the 3-4 fork and 5-6 fork are in the correct position.

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Install the right side rear shift fork support bolts (1).

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Install the left side rear shift fork support bolts (1) and tighten both side shift fork support bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Remove the cover plug (1) and verify the oil feed tube is aligned to the cover hole. Reinstall the cover plug and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the rear case bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS . Tighten the bolts in a crisscross pattern.

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Install the rear shift fork detent balls, springs and plugs (1) to the case and tighten the shift fork detent plugs to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install the countershaft bearing snap ring service plug using (special tool #2051400210, Socket, Allen 27 mm) (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Install a NEW front input seal using (special tool #2052000210, Installer, Seal Input Shaft) (1).
NOTE:
Verify the front input seal installed depth is within specification. Refer to GENERAL SPECIFICATIONS .

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Install the input shaft sleeve (2) and the input shaft sleeve bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
Install the range position switch.
Refer to SWITCH, RANGE POSITION, REMOVAL AND INSTALLATION .

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Install the rear output bearing (2) and the NEW output shaft lock nut (1). Use (special tool #2051600210, Socket, Spline Input Shaft 21 Teeth) to hold the input shaft and (special tool #2051500210, Socket, Output Shaft 60 mm) to tighten the nut to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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Stake the nut to the locknut groove (1) on the output shaft.

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Install a NEW rear oil seal using (special tool #2051900210, Installer, Seal Output Shaft) (1).
NOTE:
Verify the rear output seal installed depth is within specification. Refer to GENERAL SPECIFICATIONS .