Al6 Transmission: Notes

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.

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

NOTE:
Do not damage the case surface.

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1 - Rear Output Oil Seal

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Using a suitable tool, remove and discard the rear output oil seal.

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1 - Output Shaft Lock Nut Stake
Using a suitable tool, carefully open the stakes on the output shaft lock nut. Remove the output shaft lock nut using the special tool # 2051600210, (Spline Input Shaft 21 Teeth Socket) and the special tool # 2051500210, (Output Shaft 60 mm Socket).

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1 - Output Shaft Lock Nut

2 - Rear Output Bearing
Remove the range position switch. Refer to SWITCH, RANGE POSITION, REMOVAL AND INSTALLATION .
Remove the output shaft lock nut and the rear output bearing. DISCARD the output shaft lock nut.

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1 - Rear Shift Fork Detent Plugs
Stand the transmission on the bell housing end. Remove the rear shift fork detent plugs with the balls and springs from the case.

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1 - Shift Fork Detent Spring And Sleeve

2 - Shift Fork Detent Springs
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 go to the very front, right side detent. The remaining shift fork detent springs and shift fork detent balls are all the same size and all the springs have the same tension.

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1 - Rear Shift Fork Support Bolts

2 - Left Side Front Shift Fork Pivot Bolt
Remove the rear shift fork support bolts from the left side of the transmission.

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1 - Rear Shift Fork Support Bolts

2 - Right Side Front Shift Fork Pivot Bolt
Remove the rear shift fork support bolts from the right side of the transmission.

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1 - Rear Case Bolts
Remove the rear case bolts.

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

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1 - Mainshaft Output Shaft Bearing

2 - Shim
Remove the shim from the mainshaft output shaft. If necessary, remove the mainshaft output shaft bearing.
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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1 - 3-4 Shift Fork

2 - 5-6 Shift Fork
Remove the 3-4 shift fork and the 5-6 shift fork.
NOTE:
When removing the output shaft, the needle bearing may stay inside (as shown) of the mainshaft output shaft.

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1 - Mainshaft Output Shaft
Remove the mainshaft output shaft from the mainshaft.

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1 - Input Shaft Rear Bearing
Remove the input shaft rear bearing.

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1 - Oil Feed Tubes
Remove the plastic oil feed tubes from the case.

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1 - Oil Separator Bolts
Remove the oil separator bolts.

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1 - Shift Guide Plate Bolts

2 - Shift Guide Plate
Remove the shift guide plate bolts. Remove the shift guide plate.
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.

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1 - Selector Lever Cover Assembly Bolts
Remove the selector lever cover assembly bolts.

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1 - Selector Lever Cover Assembly
Remove the selector lever cover assembly.

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1 - Inner Shift Lever Bolt
Remove and DISCARD the inner shift lever bolt.

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1 - Outer Shift Lever
Remove the outer shift lever.

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1 - Inner Shift Lever
Remove the inner shift lever.

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1 - Front Shift Fork Detent Plugs

Remove the front shift fork detent plugs with the balls and springs. DISCARD the front shift fork detent plugs.

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1 - Right Side Rear Shift Fork Support Bolts

2 - Right Side Front Shift Fork Pivot Bolt

Remove and DISCARD the right side front shift fork pivot bolt.

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1 - Left Side Rear Shift Fork Support Bolts

2 - Left Side Front Shift Fork Pivot Bolt

Remove and DISCARD left side front shift fork pivot bolt.

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1 - Reverse Idler Gear Side Bolt
Remove the reverse idler gear side bolt.

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1 - Reverse Idler Gear Front Bolt
Remove the reverse idler gear front bolt.

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

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1 - Front Input Shield Bolts

2 - Front Input Shield
Remove the front input shield bolts and remove the front input shield.

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1 - Countershaft Snap Ring
Place the transmission assembly horizontally on the bench. Expand the countershaft snap ring using a suitable pair of snap ring pliers and pull countershaft slightly to the rear to move snap ring from the groove.
NOTE:
Illustration shown without mainshaft installed for clarity.

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1 - Mainshaft Snap Ring
Expand the mainshaft snap ring and pull mainshaft slightly to the rear to move the mainshaft snap ring from the groove in the bearing.
NOTE:
Hold the mainshaft and countershaft while pulling rearward to keep the snap rings from re-engaging.

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Mainshaft And Countershaft Subassembly
Remove the mainshaft and countershaft subassembly from the case.

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1 - Shift Select Shaft

2 - 1-2 Shift Fork
Remove the shift select shaft.
Remove the 1-2 shift fork.

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1 - Reverse Shift Fork And Shaft
Remove the reverse shift fork and shaft.

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1 - Reverse Idler Gear
Remove the reverse idler gear.

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1 - Oil Slinger

2 - Notches
Remove the oil slinger from the front case.

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

ASSEMBLY

NOTE:

Torque specifications are given at the bottom of the procedure.

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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1 - Front Seal

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

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1 - Oil Slinger

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

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1 - Oil Separator

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

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1 - Reverse Shift Fork And Shift Rail
Loosely install the reverse shift fork and shift rail into the transmission case. Verify the shift fork is seated in the groove of the sleeve in the correct orientation.

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1 - Mainshaft
Loosely install the mainshaft on top of the countershaft.

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1 - Reverse Idler Gear

Install the reverse idler gear loosely in the case.

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1 - Reverse Idler Gear

2 - 1-2 Shift Fork

3 - Oil Separator

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

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1 - Shift Select Shaft

2 - 1-2 Shift Fork
Install the shift select shaft.

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

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1 - Shaft Bearings
Align the shaft bearings to the bores.

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Shaft Installation
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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1 - Countershaft Snap Ring
Open the countershaft snap ring 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.
NOTE:
Illustration shown without mainshaft installed for clarity.

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1 - Mainshaft Snap Ring

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 and seat the bearing in the bore with the snap ring in the groove on the bearing.

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1 - Left Side Rear Shift Fork Support Bolts

2 - Left Side Front Shift Fork Pivot Bolt

Install the NEW front left side shift fork pivot bolt.

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1 - Right Side Rear Shift Fork Support Bolts

2 - Right Side Front Shift Fork Pivot Bolt

Install the NEW right side front shift fork pivot bolt and torque both shift fork pivot bolts.

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1 - Reverse Idler Gear Front Bolt
Install the reverse idler gear front bolt with a NEW washer and hand tighten.

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1 - Reverse Idler Gear Side Bolt
Install the reverse idler gear side bolt with a NEW washer and torque both reverse idler bolts.

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1 - Front Shift Fork Detent Plugs
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 torque specification.

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1 - Shift Fork Detent Spring And Sleeve

2 - Shift Fork Detent Springs
The shift fork detent spring and sleeve go to the very front, right side detent. The remaining shift fork detent springs and shift fork detent balls are all the same size and all the springs have the same tension.

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1 - Inner Shift Lever
Install the inner shift lever.

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1 - Outer Shift Lever
Install the outer shift lever.

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1 - Inner Shift Lever Bolt
Install the NEW inner shift lever bolt and tighten to the proper torque specification.

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1 - Selector Lever Cover Assembly
Clean the selector lever cover assembly 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.

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1 - Selector Lever Cover Assembly
Position the select lever cover assembly to the transmission, then install the bolts and tighten to the proper torque specification.

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1 - Selector Lever Cover Assembly Bolts
Install the shift guide plate. Install the shift guide plate bolts and tighten to the proper torque specification.

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1 - Shift Guide Plate Bolts

2 - Shift Guide Plate
Install the oil separator bolts and tighten to the proper torque specification.

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1 - Oil Separator Bolts
Install the plastic oil feed tubes.

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1 - Oil Feed Tubes
Verify the tubes are seated in the oil feed locating tip and holes in the front case half.

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1 - Oil Feed Locating Tip

2 - Oil Feed Holes
Verify the oil feed tube is seated in the upper guide hole.

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1 - Oil Feed Tubes

2 - Oil Feed Tubes Upper Guide Hole
Install the 3-4 shift fork and the 5-6 shift fork on the mainshaft.

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1 - 3-4 Shift Fork

2 - 5-6 Shift Fork
Install the input shaft rear bearing.

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1 - Input Shaft Rear Bearing

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

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1 - Installer, Bearing Output Shaft 2052300210

2 - Mainshaft Output Shaft Bearing

3 - Mainshaft Output Shaft

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

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1 - Mainshaft Output Shaft
Install the output shim to the mainshaft output shaft.

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1 - Mainshaft Output Shaft Bearing

2 - Shim
Install the seal into the rear case half. Verify the seal is fully seated in the groove.

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1 - Seal
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.
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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1 - Rear Case
Install the right side rear shift fork support bolts.

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1 - Rear Shift Fork Support Bolts

2 - Right Side Front Shift Fork Pivot Bolt
Install the left side rear shift fork support bolts and tighten both side shift fork support bolts to the proper torque specification.

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1 - Rear Shift Fork Support Bolts

2 - Left Side Front Shift Fork Pivot Bolt
Remove the cover plug and verify the oil feed tube is aligned to the cover plug hole. Reinstall the cover plug and tighten to the proper torque specification.

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1 - Cover Plug Hole
Install the rear case bolts and tighten to the proper torque specification. Tighten the bolts in a crisscross pattern.

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1 - Rear Case Bolts
Install the rear shift fork detent balls, springs and plugs to the case and tighten the shift fork detent plugs to the proper torque specification.

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1 - Rear Shift Fork Detent Plugs
Install the countershaft bearing snap ring service plug using special tool # 2051400210, (Allen 27 mm Socket) and tighten to the proper specification. Refer to: TORQUE SPECIFICATIONS - AL6 MANUAL TRANSMISSION .

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1 - Socket, Allen 27 mm 2051400210
Install a NEW front input seal using special tool # 2052000210, (Seal Input Shaft Installer).
NOTE:
Verify the front input seal installed depth is within specification. Refer to: TORQUE SPECIFICATIONS - AL6 MANUAL TRANSMISSION .

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1 - Installer, Seal Input Shaft 2052000210
Install the input shaft sleeve and the input shaft sleeve bolts and tighten to the proper torque specification.

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1 - Front Input Shield Bolts

2 - Front Input Shield
Install the range position switch. Refer to SWITCH, RANGE POSITION, REMOVAL AND INSTALLATION .
Install the rear output bearing and the NEW output shaft lock nut. Use special tool # 2051600210, (Spline Input Shaft 21 Teeth Socket) to hold the input shaft and special tool # 2051500210, (Output Shaft 60 mm Socket) to tighten the nut to the proper torque specification.

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1 - Output Shaft Lock Nut

2 - Rear Output Bearing
Stake the nut to the locknut groove on the output shaft.

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1 - Output Shaft Lock Nut Stake
Install a NEW rear oil seal using special tool # 2051900210, (Seal Output Shaft Installer).
NOTE:
Verify the rear output seal installed depth is within proper specification. Refer to: TORQUE SPECIFICATIONS - AL6 MANUAL TRANSMISSION .

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1 - Installer, Seal Output Shaft 2051900210