Part 1

ASSEMBLY

MAINSHAFT





1. Install mainshaft center support bearing (1) on mainshaft (2).




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




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




4. Install sixth gear clutch body (1) on sixth gear (2).




5. Install sixth gear friction ring (1) on clutch body (2).




6. Install 5-6 synchronizer hub (1) on mainshaft with Installer W-262 (2).




7. Install 5-6 synchronizer hub (1) snap ring (2).




8. Install 5-6 synchronizer detents (1) in hub (2).




9. Install 5-6 synchronizer sleeve (1) on hub (2).

NOTE: Align grooves in the sleeve with detents in hub.




10. Install fifth gear synchronizer friction ring (1) on 5-6 synchronizer hub (2).




11. Install fifth gear synchronizer clutch body (1) on 5-6 synchronizer hub (2).

COUNTERSHAFT





1. Install countershaft center support bearing (1) on countershaft (2).

CENTER SUPPORT





1. Install center support (1) countershaft roller bearing race with Installer/Remover 9617 (2) and Handle C-4171.




2. Install center support (1) mainshaft roller bearing race with Installer/Remover 9668 (2) and Handle C-4171.




3. Install center support (1) race retainer screw (2) and tighten to 22 Nm (16 ft. lbs.).

REAR HOUSING





1. Install mainshaft bearing (1) in rear housing with hammer and driver.
2. Install mainshaft bearing (1) retainer (2). Apply Mopar(R) Lock & Seal Adhesive or equivalent to retainer bolts and tighten to 10 Nm (88 in. lbs.).




3. Install shift rail roller bearing (1) with Installer 8475 (2).




4. Install countershaft bearing with Installer 9624 (1) and Handle C-4171 (2).




5. Install idler gear (1) in rear housing (2).




6. Install idler gear bearing (1) in idler gear (2).




7. Install idler gear (1) shaft support (2).




8. Install idler gear (2) shaft (1).




9. Install shaft bolt and align idler gear shaft (1) with shaft bolt (2).




10. Apply Mopar(R) Lock & Seal Adhesive or equivalent to idler shaft bolt. Tighten bolt (1) in housing (2) to 25 Nm (18 ft. lbs.).

FRONT HOUSING





1. Install mainshaft and countershaft bearings in front housing with hammer and driver.
2. Install mainshaft bearing retainer (1) and countershaft bearing retainers (2). Apply Mopar(R) Lock & Seal Adhesive or equivalent to retainer bolts and tighten to 10 Nm (88 in. lbs.).




3. Install mainshaft (1) and countershaft (2) in build Fixture 9626 (3).




4. Install input shaft bearing (1) on mainshaft (2).




5. Install input shaft (1) on mainshaft (2).




6. Install 5-6 shift rail (1) and 3-4 shift rail (2) in build Fixture 9626. Then install 5-6 shift fork (3) and 3-4 shift fork (4)





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

CAUTION: A bearing heater (3) is used to heat Plug 9625 (1) and Plug 9619-1 (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 177 Celsius (212� Min. - 350� 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.

7. Heat Plug 9625 (1) and Plug 9619-1 (2) to a maximum of 177 Celsius (350� Fahrenheit) with bearing heater (3).




8. With tongs place heated Plug 9625 in countershaft bearing and heated Plug 9619-1 into mainshaft bearing. Allow plugs to heat bearings for two minutes.




9. Remove Plug 9625 and Plug 9619 with welding gloves or tongs, then install front housing (1) on mainshaft and countershaft in fixture (2).




10. Apply Mopar(R) Lock & Seal Adhesive or equivalent to shift fork pivot bolts. Install 5-6 (1) and 3-4 (2) shift fork pivot bolts, in both sides of the front housing and tighten to 35 Nm (26 ft. lbs.).

NOTE: Verify shift fork pivot holes are aligned with pivot bolt holes before installing bolts.




11. Install two detents (1) in the side of the front housing (2).