Assembly
ASSEMBLY TAIL HOUSING1. Install idler gear shaft.
2. Install thrust washer, gear and bearing (Fig. 51).
3. Apply Loctite 242 to idler gear bracket bolts. Install idler gear bracket and bolts (Fig. 52) and tighten bolts to 24 Nm (15 ft. lbs.).
CLUSTER EXTENSION
1. Install caged needle bearing (Fig. 53).
2. Install gear and 5-6 synchronizer sleeve (Fig. 54).
3. Install new snap ring (Fig. 55).
CAUTION: Do not reuse original snap ring.
4. Install bearing spacer (Fig. 56).
MAIN SHAFT
CAUTION: Main shaft snap rings are not interchangeable.
1. Press third gear and 3-4 synchronizer hub and sleeve onto the mainshaft.
2. Install 3-4 synchronizer original or new snap ring (Fig. 57).
3. Press second gear and synchronizer hub onto the main shaft.
4. Install 1-2 thrust washer and blocker ring assembly onto the main shaft (Fig. 58).
5. Install the original or new 1-2 snap ring onto the main shaft (Fig. 59).
6. Install first gear and bearing onto the main shaft (Fig. 60).
7. Install rear main shaft tapered bearing (Fig. 61).
TRANSMISSION HOUSING
NOTE: During assembly refer to Adjustments for Main Shaft Bearing, Cluster Gear Bearing and Counter Shaft Extension End Play.
1. Install input shaft into the front adapter (Fig. 62).
2. Install cluster gear assembly into the front adapter (Fig. 63).
3. Tilt cluster gear sideways then install main shaft and shift rail assemblies into the adapter (Fig. 64).
4. Install reverse rail assembly (Fig. 65).
5. Apply Mopar Gasket Maker to the adapter sealing surface.
6. Install transmission case on front adapter (Fig. 66).
7. Install front adapter bolts (Fig. 67) and tighten to 34 Nm (25 ft. lbs.).
8. Install two torx screws located on-the top of the transmission case (Fig. 68).
9. Install 5-6 driven gear.
10. Assemble offset lever, spring, steel ball and guide plate.
11. Slide offset lever and guide plate onto the rear of the transmission (Fig. 69).
12. Install two torx bolts to guide plate and tighten to 22 Nm (15 ft. lbs.) (Fig. 70).
13. Drive roll pin down into offset lever (Fig. 71).
14. Apply Loctite 242 to shift detente threads. Install shift detente assembly with new O-ring and tighten to 34 Nm (25 ft. lbs.) (Fig. 72).
15. Slide skip shift lever onto shaft. Install roll pin from skip shift lever (Fig. 73).
NOTE: Ensure skip shift lever is installed in the correct direction.
16. Apply Mopar Gasket Maker to the top plate sealing surface.
17. Install top plate bolts and tighten to 20 Nm (15 ft. lbs.).
18. Install sixth gear, bearing and thrust washer (Fig. 74).
19. Install shift fork and 5-6 synchronizer sleeve (Fig. 75).
20. While holding 5-6 shift fork in place, install cluster extension shaft (Fig. 76).
21. Install new 5-6 gear shift fork snap ring (Fig. 77).
22. Install shift fork and synchronizer sleeve onto main shaft (Fig. 78).
23. Install synchronizer sleeve snap ring (Fig. 79).
24. Install new reverse shift fork snap ring (Fig. 80).
NOTE: Use a new snap ring with the flat side facing rearward.
25. Install reverse gear, bearing, wave washer and brass synchronizer ring (Fig. 81).
26. Install reverse gear thrust washer and snap ring (Fig. 82).
27. Install main shaft roller bearing, spacers and snap ring (Fig. 83).
28. Install speed sensor tone wheel and snap rings (Fig. 84).
29. Apply Mopar Gasket Maker to the Tail housing sealing surface.
30. Install the six tail housing to main case bolts (Fig. 85). Tighten the bolts to 41 Nm (30 ft. lbs.).
31. Install two tail housing nuts located at the top of the transmission tail housing (Fig. 86).
32. Install new O-ring in speed sensor housing bore. Install speed sensor in the tail housing and tighten mounting bolt to 11 Nm (95 in. lbs.) (Fig. 87).
33. Slide offset lever onto shaft (Fig. 88).
34. Install offset lever roll pin (Fig. 89).
35. Install Mopar Gasket Maker to the shift cover sealing surface and position cover on the transmission (Fig. 90).
36. Install shift cover four mounting bolts and tighten to 11 Nm (15 ft. lbs.).