Rear Housing Installation 2WD

REAR HOUSING INSTALLATION

Preparing Rear Housing Dowels For Installation:

1. Drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface.
2. Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race.

Lubricating Countershaft Rear Bearing:

3. Install countershaft rear bearing in bearing race.

Countershaft Rear Bearing Seated In Race:

CAUTION: The countershaft bearings can be installed backwards if care is not exercised. Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing.

4. Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed.
5. Apply light coat of petroleum jelly to shift shaft bushing/bearing in rear housing.
6. Reach into countershaft rear bearing with finger, and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place. This avoids having rollers becoming displaced during housing installation. This will result in misalignment between bearing and countershaft, bearing hub.

Rear Housing Installation-2WD:

7. Install rear housing onto geartrain. Be sure bearing retainer pilot stud is in correct bolt hole in housing. Also be sure countershaft and output shaft bearings are aligned in housing and on countershaft. It may be necessary to lift upward on countershaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages the housing.
8. Seat rear housing on output shaft rear bearing and countershaft. Use plastic or rawhide mallet to tap housing into place.
9. Install the three bolts that secure rear bearing retainer to rear housing as follows:

Applying Sealer To Retainer And Housing Bolts:

a. Apply MOPAR Gasket Maker, or equivalent, to bolt threads, bolt shanks and under bolt heads.

Removing Pilot Stud Tool And Installing Retainer Bolts-2WD:

b. Start first two bolts in retainer. It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer.
c. Remove Pilot Stud 8120 and install last retainer bolt.
d. Tighten all three retainer bolts to 30 - 35 Nm (22 - 26 ft. lbs.) torque.