Disassembly

DISASSEMBLY

FRONT HOUSING
1. Shift transmission into Neutral.
2. Remove drain plug and drain lubricant into a container.





3. Remove backup light switch (Fig. 3).





4. Remove shift tower bolts and remove tower and lever assembly (Fig. 4).





5. Remove shift shaft lock bolt (Fig. 5). Bolt secures the shift shaft bushing and lever.





6. Remove shift shaft detent plug with Remover 8117A (Fig. 6).
7. Remove shift shaft detent plunger and spring with a pencil magnet.





8. Remove input shaft bearing retainer bolts (Fig. 7).





9. Remove bearing retainer from input shaft with a pry tool (Fig. 8).





10. Remove snap ring securing input shaft in front bearing (Fig. 9).





11. Remove front housing bolts (Fig. 10). Leave one bolt in place until geartrain is ready to be removed from case. Three bolts at the rear of housing are for the output shaft bearing retainer.
12. Tap front housing off alignment dowels with a plastic mallet and separate the housing.





13. Remove input shaft bearing (Fig. 11).





14. Note position of input shaft, shift shaft, forks, and geartrain components in housing (Fig. 12).

SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER





1. Drive out roll pin that secures shift bushing and lever to shift shaft with a hammer and punch (Fig. 13).
2. Position shift socket off to the side so roll pin removal does not interfere with gears.
3. Drive out shift socket roll pin with a hammer and punch.

NOTE: Use proper size punch to prevent damage to the shift shaft.





4. Pull shift shaft straight out of rear housing and shift forks (Fig. 14).





5. Remove shift socket from rear housing (Fig. 15).





6. Remove lever and bushing (Fig. 16).





7. Rotate 3-4 fork around synchro sleeve until fork clears shift arms on 1-2 and fifth-reverse forks, then remove 3-4 fork (Fig. 17).





8. Remove front reverse idler shaft support bolt and loosen rear bolt (Fig. 18).
9. Remove reverse idler shaft support by sliding it straight out of housing.
10. Remove rear reverse idler shaft bolt.





11. Remove reverse idler shaft, idler gear, bearing and thrust washer (Fig. 19).

GEARTRAIN





1. Remove output shaft bearing retainer bolts (Fig. 20).





2. Hold the geartrain while lifting the rear housing off (Fig. 21).

GEARTRAIN
1. Remove 1-2 and fifth-reverse forks from synchro sleeves.
2. Separate countershaft from mainshaft.
3. Separate input shaft from output shaft.

COUNTERSHAFT
1. Remove countershaft front and rear bearing with Puller 8356.
2. Remove rear bearing race (in rear housing) with Bearing Race Remover L-4454. Install new race with Driver C-4656 and Driver Handle C-4171.
3. Remove bearing shim cap from front housing (below input shaft bearing retainer). Remove shim. Drive race through and out of housing with Driver C-4656 and Driver Handle C-4171. Install new race into housing from outside. Do not drive all the way into position. Tightening the shim cap will install the race to the proper position. Install shim and shim cap and torque cap bolts to 28.5 Nm (21 ft. lbs.).

OUTPUT SHAFT

NOTE: Synchronizer hubs and sleeves are different. Remove synchronizer unit as an assembly to avoid intermixing parts. Mark each synchro hub and sleeve for assembly reference.

1. Remove snap ring that secures 3-4 synchro hub on output shaft.
2. Remove 3-4 synchro assembly, third gear synchro ring and third gear with a shop press and Splitter 1130. Position splitter between second and third gears.





3. Remove third gear needle bearing (Fig. 22).
4. Remove retaining ring that secures two-piece thrust washer on shaft.





5. Remove two-piece thrust washer (Fig. 23). Note position of washer locating lugs in shaft notches for installation reference.





6. Remove second gear and needle bearing (Fig.24).
7. Remove 2nd-3rd gear thrust washer locating pin.
8. Remove second gear synchro ring and synchro cone.
9. Remove 1-2 synchro hub snap ring.





10. Remove 1-2 synchro hub and sleeve and first gear from output shaft with shop press and Splitter 1130 (Fig. 25). Position splitter between first and reverse gears.





11. Remove first gear needle bearing (Fig. 26).





12. Remove output shaft bearing snap ring (Fig. 27).
13. Remove output shaft bearing from shaft with shop press and Splitter 1130. Position splitter between bearing and fifth gear.





14. Remove fifth gear (Fig. 28).





15. Remove fifth gear needle bearing. Spread bearing apart just enough to clear shoulder on output shaft (Fig. 29).





16. Remove fifth-reverse synchro hub snap ring (Fig. 30).





17. Remove fifth-reverse synchro hub and sleeve with shop press (Fig. 31).





18. Remove reverse gear and needle bearing (Fig.32).

CLEANING
Clean the gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed air. Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk, or similar solvents. Do not dry the bearings with compressed air. Allow the bearings to either air dry, or wipe them dry with clean shop towels.

INSPECTION

NOTE: Minor nicks on the surface can be smoothed off with 320/420 grit emery cloth and final polished with oil coated crocus cloth.

SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball or internal components are worn or damaged.

SHIFT SHAFT AND FORKS





Inspect the shift fork interlock arms and synchro sleeve contact surfaces (Fig. 33). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks.
Check condition of the shift shaft detent plunger and spring. The plunger should be smooth and free of nicks or scores. Replace the plunger and spring if in doubt about condition. Check condition of detent plunger bushings. Replace if damaged.
Inspect the shift shaft, shift shaft bushing and bearing. The shaft lever and the lever bushing that fits over the lever.
Replace the shaft if bent, cracked or severely scored. Replace the shift shaft bushing or bearing if damaged. Replace the shaft lever and bushing if either part is deformed or worn. Do not attempt to salvage these parts as shift fork binding will occur. Replace the roll pin that secures the lever to the shaft.

FRONT/REAR HOUSINGS AND BEARING RETAINERS
Clean the gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk or similar solvents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
Inspect the housings carefully for cracks, stripped threads, scored mating surfaces, damaged bearing bores or worn dowel pin holes.

NOTE: The front housing contains the countershaft front bearing race. The rear housing contains the countershaft rear bearing race. If a countershaft bearing failure results, the bearing races must be replaced also.

Inspect input shaft bearing retainer. Be sure the release bearing slide surface of the retainer is in good condition. Replace the retainer seal if necessary. Inspect output shaft bearing retainer. Be sure the U-shaped retainer is flat and free of distortion. Replace the retainer if the threads are damaged or if the retainer is bent or cracked.

COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings are standard tapered roller bearings with matching races. The races are pressed into the front and rear housings. Inspect countershaft bearings and races for abnormal wear or damage.

REVERSE IDLER COMPONENTS





Inspect idler gear, bearing, shaft, thrust washer and support for excessive wear or failure (Fig. 34). Replace bearing if any of the needle bearing rollers are worn, chipped, cracked, flat-spotted or brinnelled. Also replace the bearing if the plastic bearing cage is damaged or distorted.
Replace thrust washer, if cracked, chipped or worn. Replace idler gear if the teeth are chipped, cracked or worn thin. Replace shaft if worn, scored or the bolt threads are damaged beyond repair. Replace support segment if cracked or chipped and replace the idler attaching bolts if the threads are damaged.

Shift Socket
Inspect shift socket for wear or damage. Replace socket if the roll pin or shift shaft bores are damaged. Replace socket if the ball seat is worn, or cracked. Do not reuse the original shift socket roll pin. The socket roll pin is approximately is approximately 33 mm (1-1/4 in.) long.

Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or broken teeth. Check condition of the bearing bore in each gear. The bores should be smooth and free of surface damage. Discoloration of the gear bores is a normal occurrence and is not a reason for replacement. Replace gears only when tooth damage has occurred or if the bores are brinnelled or severely scored.
Inspect shaft splines and bearings surfaces. Replace the shaft if the splines are damaged or bearing surfaces are deeply scored, worn or brinnelled.