Assembly
MANUAL TRANSMISSION - NSG370ASSEMBLY
MAINSHAFT
1. Place mainshaft in Fixture 9648 mounted in a vise.
Fig. 60 SECOND GEAR BEARING:
2. Install second gear bearing (1) (Fig. 60) on mainshaft (2).
Fig. 61 SECOND GEAR:
3. Install second gear (1) (Fig. 61) on bearing (2).
Fig. 62 2ND INNER FRICTION RING:
4. Install inner synchronizer friction ring (1) (Fig. 62) on second gear (2).
Fig. 63 2ND OUTER FRICTION RING:
5. Install outer synchronizer friction ring (1) (Fig. 63) on second gear (2).
Fig. 64 2ND BLOCKER RING:
6. Install synchronizer blocker ring (1) (Fig. 64) on second gear (2).
Fig. 65 1-2 SYNCHRONIZER HUB INSTALLER:
7. Install 1-2 synchronizer hub (1) (Fig. 65) with Installer 8228 (2) and a press. Align hub detent openings with synchronizer rings.
Fig. 66 1-2 SYNCHRO HUB SNAP RING:
8. Install 1-2 synchronizer hub (1) (Fig. 66) snap ring (2).
NOTE: Reuse original snap ring or thickest snap ring that will fit.
Fig. 67 1-2 SYNCHRO SLEEVE:
9. Install 1-2 synchronizer sleeve (1) (Fig. 67) and push to the bottom of the synchronizer hub (2).
Fig. 68 1-2 SYNCHRO DETENT:
10. Install 1-2 synchronizer detents, springs, and balls (2) (Fig. 68).
Fig. 69 FIRST GEAR BLOCKER RING:
11. Install first gear blocker ring (1) (Fig. 69) into synchronizer hub (2).
Fig. 70 FIRST GEAR FRICTION RING:
12. Install first gear outer friction ring (1) (Fig. 70) into synchronizer hub (2).
Fig. 71 FIRST GEAR INNER FRICTION RING:
13. Install first gear inner friction ring (1) (Fig. 71) into synchronizer hub (2).
Fig. 72 1ST GEAR AND BEARING:
14. Install first gear (1) (Fig. 72) and bearing (2). Then center 1-2 synchronizer sleeve on synchronizer hub.
WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.
CAUTION: A bearing heater is used to assemble first gear thrust washer (1) and reverse gear bearing race (2). Use only a bearing heater/hot plate and follow manufacturer'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.
Fig. 73 WASHER AND RACE:
15. Heat first gear thrust washer (1) (Fig. 73) and reverse gear bearing race (2) with bearing heater.
Fig. 74 THRUST WASHER & RACE:
16. Using welding gloves or tongs, install first gear thrust washer (1) (Fig. 74) then reverse gear bearing race (2).
Fig. 75 REVERSE GEAR:
17. Install reverse gear (1) (Fig. 75) and bearing (2).
Fig. 76 REVERSE SYNCHRONIZER:
18. Install reverse gear (1) (Fig. 76) synchronizer friction ring (2).
Fig. 77 REVERSE HUB INSTALLER:
19. Install reverse gear synchronizer hub (1) on mainshaft with Installer W-262 (2) and a press. Align hub detent opening (3) with friction ring (4) lug (Fig. 77).
Fig. 78 REVERSE SYNCHRO HUB DETENT:
20. Install reverse gear synchronizer hub (1) (Fig. 78) detents (2).
Fig. 79 REVERSE GEAR SYNCHRO SLEEVE:
21. Install reverse gear (1) (Fig. 79) synchronizer sleeve (2) and center sleeve on synchronizer hub.
22. Remove mainshaft from Fixture 9648. Turn fixture over in the vise, then install opposite end of mainshaft in the fixture.
Fig. 80 SIXTH GEAR AND BEARING:
23. Install sixth gear (1) (Fig. 80) and bearing (2).
Fig. 81 6TH GEAR BLOCKER RING:
24. Install sixth gear synchronizer blocker ring (1) (Fig. 81) on sixth gear (2).
Fig. 82 6TH GEAR FRICTION RING:
25. Install sixth gear synchronizer friction ring (1) (Fig. 82) on sixth gear (2).
Fig. 83 5-6 HUB INSTALLER:
26. Install 5-6 synchronizer hub (1) with Installer W-262 (2). Align hub detent opening (3) with friction ring lugs (4) and press hub on mainshaft (Fig. 83).
NOTE: 5-6 synchronizer hub center, is offset and must be install large offset down.
Fig. 84 5-6 SYNCHRO HUB SNAP RING:
27. Install 5-6 synchronizer hub (1) (Fig. 84) snap ring (2).
NOTE: Reuse original snap ring or thickest snap ring that will fit.
28. Install 5-6 synchronizer sleeve on hub (1).
REAR HOUSING
Fig. 85 REAR COUNTERSHAFT BEARING:
1. Install countershaft bearing (Fig. 85) into rear housing with Installer 9643 (1) and Handle C-4171.
Fig. 86 REAR HOUSING MAINSHAFT BEARING:
2. Install mainshaft bearing (1) (Fig. 86) into housing (2).
3. Install bearing retainer and tighten bolts to 10 Nm (88 inch lbs.).
Fig. 87 REVERSE IDLER GEAR:
4. Install reverse idler gear (1) (Fig. 87) into housing (2).
Fig. 88 IDLER GEAR BEARING:
5. Install idler gear (1) (Fig. 88) bearing (2) into gear.
Fig. 89 IDLER GEAR THRUST WASHER:
6. Install idler gear (1) (Fig. 89) thrust washer (2) on idler gear.
Fig. 90 IDLER SHAFT SUPPORT:
7. Install idler gear (1) (Fig. 90) shaft support (2) into housing.
Fig. 91 IDLER GEAR SHAFT:
8. Install idler gear (1) (Fig. 91) shaft (2) with shaft bolt hole aligned with shaft support hole (3).
Fig. 92 IDLER SHAFT BOLT:
9. Install idler gear shaft bolt (1) (Fig. 92) into the housing (2) and tighten to 20 Nm (15 ft. lbs.).
Fig. 93 OUTPUT SHAFT SEAL 4X4:
10. Install 4x4 output shaft seal into rear housing (1) with Installer 9638 (2) (Fig. 93). Install 4x2 output shaft seal into rear housing with Installer 9635 and Installer 6448A.
INPUT SHAFT
Fig. 94 INPUT SHAFT BEARING LIP:
1. Install input shaft bearing (1) (Fig. 94) on input shaft with the bearing retainer lip (2) facing fifth gear.
Fig. 95 INPUT SHAFT BEARING INSTALLER:
2. Install input shaft bearing (1) (Fig. 95) with Installer 6448A (2) and a press.
Fig. 96 INPUT SHAFT BEARING SNAP RING:
3. Install input shaft bearing (1) snap-ring (2) (Fig. 96).
NOTE: Reuse original snap ring or thickest snap ring that will fit.
FRONT HOUSING
Fig. 97 INPUT SHAFT SEAL INSTALLER:
1. Install input shaft seal (Fig. 97) with Installer 9635 (1) Installer 6448A (2).
Fig. 98 INPUT SHAFT IN HOUSING:
2. Install input shaft (1) (Fig. 98) with bearing (2) into housing.
Fig. 99 INPUT SHAFT BEARING RETAINER:
3. Install input shaft (1) (Fig. 99) bearing retainers (2, 3) and tighten bolts to 10 Nm (88 inch lbs.).
Fig. 100 INPUT SHAFT RETAINER:
4. Install input shaft retainer (1) (Fig. 100) and tighten bolts (2) to 9 Nm (80 inch lbs.).
Fig. 101 BEARING RETAINER LIP:
5. Install countershaft bearing (1) (Fig. 101) into housing with bearing retainer lip (2) facing up.
Fig. 102 COUNTERSHAFT BEARING RETAINER:
6. Install countershaft bearing (1) (Fig. 102) retainers (2) and tighten bolts to 10 Nm (88 inch lbs.).
FINAL ASSEMBLY
Fig. 103 MAINSHAFT IN FIXTURE:
1. Install mainshaft (1) onto Build Fixture 9633 (2) (Fig. 103).
Fig. 104 COUNTERSHAFT IN FIXTURE:
2. Install countershaft (1) onto Build Fixture 9633 (2) (Fig. 104).
Fig. 105 OIL SLINGER:
3. Install oil slinger (3) on countershaft (2) between reverse (1) and first gear (4) (Fig. 105).
Fig. 106 SHIFT RAILS/FORKS IN FIXTURE:
4. Install shift rails and forks (1) onto Fixture 9633 (2) and countershaft/mainshaft. (Fig. 106).
Fig. 107 MAINSHAFT INSTALLER:
5. Install rear housing on mainshaft (1) (Fig. 107) with Installer 9636 (2).
6. Remove rear housing with mainshaft, countershaft and shift rails from fixture. Set assembly on rear housing with shafts pointing up.
Fig. 108 5-6 SYNCHRONIZER DETENTS:
7. Install 5-6 synchronizer hub (1) (Fig. 108) detents, springs, and balls (2).
Fig. 109 FIFTH GEAR FRICTION RING:
8. Install fifth gear synchronizer friction ring (1) (Fig. 109) on 5-6 synchronizer hub (2).
Fig. 110 FIFTH GEAR BLOCKER RING:
9. Install fifth gear (Fig. 110) blocker ring (1) on 5-6 synchronizer hub (2). Then hold blocker ring and center synchronizer sleeve.
Fig. 111 INPUT SHAFT ROLLER BEARING:
10. Install input shaft (Fig. 111) roller bearing (1) on mainshaft (2)..
Fig. 112 SHIFT RAIL SUPPORT PLATE:
11. Install shift rail (1) (Fig. 112) support plate (2) bolts and tighten to 8 Nm (71 inch lbs.).
12. Apply MOPAR Gasket Maker to front housing.
Fig. 113 SPLIT HOUSING:
13. Install front housing (1) (Fig. 113) on rear housing (2) and tighten bolts to 28 Nm (20 ft. lbs.).
Fig. 114 OUTPUT SHAFT SNAP RING:
14. Install output shaft (1) (Fig. 114) snap ring (2) 4x4 only.
Fig. 115 OUTPUT SHAFT SEAL:
15. Install output shaft (1) (Fig. 115) seal (2) in rear housing with Installer 9638.
Fig. 116 SHIFT TOWER OPENING:
16. Through the shift tower opening (1) (Fig. 116) move two shift rails (2) forward to lock the transmission in two gear.
Fig. 117 COUNTERSHAFT BOLT:
17. Install countershaft bolt (1) (Fig. 117) into the front housing (2) and tighten to 100 Nm (74 ft. lbs.).
Fig. 118 COUNTERSHAFT PLUG:
18. Install countershaft plug (1) (Fig. 118) in front housing (2) with Installer 7828-A and Handle C-4171.
19. Move shift rails to neutral.
20. Apply MOPAR Gasket Maker to shift tower.
Fig. 119 SHIFT TOWER:
21. Install shift tower (1) (Fig. 119) and tighten bolts (2) to 14 Nm (10 ft. lbs.).
Fig. 120 BACK UP LAMP SWITCH:
22. Install back up lamp switch (1) and bolt (2) (Fig. 120).