Part 1
ASSEMBLYSealers are used at all case joints. Use Mopar Gasket Maker for all case joints and Mopar silicone sealer or equivalent, for the input shaft bearing retainer. Apply these products as indicated in the assembly procedures.
CAUTION: The transmission shift components must be in the Neutral position during assembly. This prevents damage to the synchro and shift components when the housings are installed.
SYNCHRONIZER
To assemble each synchro install the springs, struts and detent balls one at a time as follows:
1. Slide the sleeve part way onto the hub. Leave enough room to install the spring in the hub and the strut in the hub groove.
2. Install the first spring in the hub. Then install a strut over the spring. Be sure the spring is seated in the spring bore in the strut.
3. Slide the sleeve onto the hub just far enough to hold the first strut and spring in place.
4. Place the detent ball in the top of the strut. Then carefully work the sleeve over the ball to hold it in place. Use a small flat blade screwdriver to press the ball into place while moving the sleeve over it.
5. Repeat the procedure for the remaining springs, struts and balls. Tape or rubber band each strut and ball to temporarily secure as they are installed.
6. Verify synchro springs, struts and detent balls are all in place (Fig. 55).
OUTPUT SHAFT
Lubricate shaft, gears and bearings with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place. Check bearing surfaces of output shaft for nicks or scratches. Smooth surfaces with 320/400 grit emery cloth if necessary. Apply oil to emery cloth and shaft surface before polishing.
Inspect and replace any synchro ring if worn or damage. Immerse each synchro ring in lubricant before installation.
1. Lubricate and install reverse gear needle bearing on shaft (Fig. 56). Slide bearing up against shoulder on output shaft.
2. Install reverse gear over needle bearing (Fig. 57).
3. Install brass synchro ring on reverse gear (Fig. 58).
4. Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.
CAUTION: One side of the hub has shoulders around the hub bore, this side of the hub faces the front of the shaft. One side of the sleeve is tapered the tapered side faces the front of the shaft.
5. Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with a press and Cup 6310-1 (Fig. 59).
6. Install new fifth-reverse hub snap ring (Fig. 60) and verify the snap ring is seated.
NOTE: Snap rings are available in thicknesses from 2.00 mm to 2.20 mm (0.078 to 0.086 inch). Install thickest snap ring that will fit in shaft groove.
7. Install fifth gear synchro ring in synchro hub and sleeve (Fig. 61).
8. Install fifth gear bearing, spreading bearing only enough to clear shoulder on output shaft (Fig. 62). Verify bearing is properly seated.
9. Install fifth gear on shaft and onto bearing (Fig. 63).
10. Invert output shaft and set the shaft in Cup 6310-1 so that fifth gear is seated on the tool (Fig. 64).
11. Install first gear bearing on output shaft (Fig. 64). Verify bearing is seated on shaft shoulder and is properly joined.
12. Install first gear on shaft and over bearing with bearing synchro cone facing up (Fig. 65).
13. Install first gear synchro ring (Fig. 66).
14. Assemble 1-2 synchro hub sleeve, springs, struts and detent balls.
CAUTION: The 1-2 synchro hub and sleeve can be installed backwards. One side of the synchro sleeve is marked First Gear Side. Verify this side of the sleeve is facing first gear.
15. Start 1-2 synchro assembly on shaft by hand (Fig. 67). Verify synchro sleeve is properly positioned.
16. Press 1-2 synchro, onto output shaft using suitable size pipe tool and shop press (Fig. 68).
CAUTION: Align the synchro ring and sleeve as hub the is being pressed onto the shaft. The synchro ring can crack if not aligned.
17. Install interim ring.
18. Install new 1-2 synchro, hub snap ring (Fig. 69) and verify the snap ring is seated.
NOTE: Snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 inch). Install thickest snap ring that will fit in shaft groove.
19. Install second gear synchro ring in 1-2 synchro hub and sleeve (Fig. 70). Verify synchro ring is properly seated.
20. Install synchro friction cone and synchro cone in synchro, ring.
21. Install second gear needle bearing on shaft (Fig. 71).
22. Install second gear onto shaft and bearing (Fig. 72). Verify second gear is fully seated on synchro components.
23. Install two-piece thrust washer (Fig. 73). Ensure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. Verify i.d. grooves and markings noted during removal are facing the correct direction.
24. Start retaining ring around two-piece thrust washer (Fig. 74). Ensure locating dimple is between the thrust washer halves.
25. Seat thrust washer retaining ring with plastic mallet (Fig. 75).
26. Install third gear needle bearing on shaft (Fig. 76).
27. Install third gear on shaft and bearing (Fig. 77).
28. Install third speed synchro ring on third gear (Fig. 78).
29. Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls.
30. Start 3-4 synchro hub on output shaft splines by hand (Fig. 79).
CAUTION: The 3-4 synchro hub and sleeve can be installed backwards. One side of the sleeve has grooves in it. This side of sleeve faces the front of the shaft.
31. Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 80).
NOTE: Place the pipe on hub as close to output shaft as possible without contacting the shaft splines.
32. Install 3-4 synchro hub snap ring (Fig. 81)and verify snap ring is seated.
NOTE: Snap rings are available in thicknesses from 2.00 mm to 2.30 mm (0.078 to 0.090 inch). Install thickest snap ring that will fit in shaft groove.
33. Install output shaft bearing.
34. Install output shaft bearing snap ring, spreading it just enough to install it (Fig. 82). Verify snap ring is seated in shaft groove.
35. Verify position of synchro sleeves before proceeding with assembly operations (Fig. 83). Grooved side of 3-4 sleeve should be facing forward. First gear side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.
REVERSE IDLER ASSEMBLY
1. Lubricate idler components with gear lube.
2. Slide idler gear bearing on shaft (Fig. 84). Bearing fits either way on shaft.
3. Slide gear onto shaft. Side of gear with recess goes to rear (Fig. 84).
4. Place first lock ball in dimple at rear end of idler shaft (Fig. 84). Hold ball in place with petroleum jelly.
5. Slide thrust rear thrust washer onto shaft and over lock ball (Fig. 85).
6. Install snap ring in groove at rear of shaft (Fig. 85).
7. Install lock ball in dimple at front of shaft. Hold ball in place with petroleum jelly.
8. Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 86).
9. Install wave washer, flat washer and remaining snap ring on idler shaft (Fig. 86). Verify snap ring is seated.
SHIFT SHAFT AND BUSHINGS/BEARINGS
Inspect shift shaft bushing and bearing for damage and replace if necessary.
1. Locate a bolt that will thread into the bushing without great effort.
2. Thread the bolt into the bushing, allowing the bolt to make its own threads in the bushing.
3. Attach a slide hammer or suitable puller to the bolt and remove bushing.
4. Use the short end of Installer 8119 to install the new bushing.
5. The bushing is correctly installed if the bushing is flush with the transmission case.
6. To replace the bearing locate a bolt that will thread into the bearing without great effort.
7. Thread the bolt into the bearing as much as possible.
8. Attach a slide hammer or suitable puller to the bolt and remove the bearing.
9. Use the short end of Installer 8119 to install the new bearing.
10. The bearing is correctly installed if the bearing is flush with the transmission case.
DETENT PLUNGER BUSHING
Inspect detent plunger bushings for damage and replace if necessary.
NOTE: The detent plunger bushings are installed to a specific depth. The space between the two bushings when correctly installed contain an oil feed hole. Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted.
1. Using the long end of Installer 8119, drive the detent bushings through the outer case and into the shift shaft bore.
2. Remove the bushings from the shift shaft bore.
3. Install a new detent plunger bushing on the long end of Installer 8118.
4. Start the bushing in the detent plunger bore in the case.
5. Drive the bushing into the bore until the tool contacts the transmission case.
6. Install a new detent plunger bushing on the short end of Installer 8118.
7. Start the bushing in the detent plunger bore in the case.
8. Drive the bushing into the bore until the tool contacts the transmission case.