Gear Case

DISASSEMBLY
1. Remove bearing retainer bolts and remove retainer.





2. Remove retainer oil seal with pry tool.





3. Remove input shaft bearing snap ring.





4. Remove cluster gear front bearing snap ring.





5. Loosen gear case by tapping it away from intermediate plate with rubber mallet.





6. Remove gear case from gear-train and intermediate plate.
7. Remove speedometer gear snap ring and remove speedometer gear and spacer from output shaft.





ASSEMBLY
1. Press front bearing on input shaft. Then secure bearing with thickest snap ring that will fit in shaft groove.





2. Press front bearing on cluster gear. Then secure bearing with thickest snap ring that will fit in ring groove on gear.





3. Install new oil seals in front bearing retainer and adapter housing. Installation depth for bearing retainer seal is 10.5 to 11.5 mm (0.414 to 0.453 inch).





4. Install reverse shaft and shaft retaining pin in adapter housing. Then install access hole plug with torx bolt.
5. Lubricate reverse shaft and gear components with MOPAR 75W-90 gear lubricant.
6. Clean mating surfaces of intermediate plate and transmission gear case with wax and grease remover. Then wipe dry with a clean cloth.





7. Apply 3 mm (1/8 inch) wide bead of MOPAR Gasket Maker, or Loctite 518 to mating surface of gear case. Keep sealer bead inside bolt holes as shown.





8. Install gear case. Align shift rails and bearings in case and tap case into position.
9. Verify that gear case is seated on intermediate plate dowel pins.





10. Install front bearing snap rings.
11. Clean gear case and front bearing retainer sealing surfaces with wax and grease remover. Then wipe dry with a clean cloth.
12. Install new seal in front bearing retainer. Then lubricate seal lip with petroleum jelly. Installation depth for seal is 10.5 to 11.5 mm (0.413 to 0.453 inch).
13. Apply a 3 mm (1/8 inch) wide bead of MOPAR Gasket Maker, or Loctite 518 to front bearing retainer sealing surface.





14. Align and install front bearing retainer. Be sure retainer is properly seated on case and bearings.
15. Install and tighten front bearing retainer bolts to 17 Nm (12 ft. lbs.) torque.