Part 2

ASSEMBLY

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

CAUTION: A bearing heater is used to assembly some components. Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100° - 149° Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and 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.

REAR HOUSING





1. Install countershaft bearing cup with Installer 9589 (1) and Handle C-4171 (2).





2. Install mainshaft bearing cup with Installer 9588 (1) and Handle C-4171 (2).
3. Install output shaft seal with Installer 9598.





4. Install reverse idler bearing (1) into idler gear (2).





5. Install idler gear (1) with taller thrust face up into rear housing (2) and off to the side. For mainshaft/countershaft installation clearance.





6. Tie strap (2) shift rails (1) together.





7. Install reverse (1), 1-2 (2) and 3-4 (3) shift rails and forks as and assembly on synchronizer sleeves.





8. Install mainshaft with shift rails (2) into the rear housing. Tilt the mainshaft then tilt the countershaft (1) into the housing.





9. Position first/reverse oil slinger (1) between the mainshaft first (2) and reverse gears, then straighten the shafts in the housing. CAUTION: Oil slinger is fragile and can crack during installation. Failure to follow these instructions will result in cracking the oil slinger and lack of oil to first/reverse bearing.






10. Position reverse idler gear and install idler shaft (2) with bolt (1).





11. Install reverse idler gear shaft bolt (1) into rear housing (2) and tighten to 58 Nm (43 ft. lbs.).





12. Install 5-6 shift shoe narrow ends (1) into the 5-6 synchronizer sleeves (2).





13. Install 5-6 shift fork (1) into the shift rail.

FRONT HOUSING





CAUTION: If mainshaft/bearings or countershaft/bearings are replaced, end-play measurements must taken to ensure proper bearing preload. Failure to follow these instructions will result in bearing damage.

1. Install input shaft seal front housing bore (1) with Installer 9595 (2).





2. Install input shaft retainer (1) and tighten bolts (2) to 23 Nm (17 ft. lbs.).





3. Install select end play shims into the countershaft bearing cup bore.
4. Install countershaft bearing cup with Installer 9589 (1) and Handle C-4171 (2).





5. Install input shaft bearing oil supply washer and select end play shims into mainshaft bearing cup bore.
6. Install mainshaft bearing cup with Installer 9588 (1) and Handle C-4171 (2).





7. Apply Mopar(TM) Gasket Maker to the rear housing sealing surface.
8. Install front housing (1) onto the rear housing (2).
9. Install housing bolts and tighten to 58 Nm (43 ft. lbs.).





10. Install 5-6 shift fork pin bolts (1) into housing and tighten to 58 Nm (43 ft. lbs.).





11. Remove shift rail (2) tie strap.





12. On a 4x2 transmission shift two shift rails to lock the transmission in two gears. Then install flange (1) on output shaft (2) and tighten bolt to 260 Nm (190 ft. lbs.). Return shift rails to neutral position.





13. Push shift tower boot (1) onto shift tower (2).





14. Apply Mopar(TM) Gasket Maker to the shift tower opening.
15. Install shift tower (2) and tighten bolts (1) to 23 Nm (17 ft. lbs.).





16. Install back up lamp switch (1) and bolt (2).