1993 DODGE TRUCK Service Repair Manual

21
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CLUTCH
GEAR J9221-89

Fig. 9 Removing Countershaft Fifth Speed Clutch Gear Snap Ring
FIFTH GEAR
SHIFT FORK
J9221-94

Fig. 10 Removing Fifth Gear Shift Fork Roil Pins
(3) Remove shift fork and fifth gear components as
assembly. Rotate mainshaft as needed to allow coun­
tershaft fifth gear to clear mainshaft fifth gear.

Removing
Countershaft
Fifth
Gear
Components
Individually
(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 9). (2) Remove countershaft fifth speed clutch gear,
stop ring and bearing spacer (Fig. 11).
(3) Remove three struts and strut springs from
countershaft fifth gear hub and sleeve (Fig. 11). (4) Remove mainshaft fifth gear nut and washer as
follows:
(a) Install Nut Wrench 6443 on fifth gear nut
(Fig. 12). Note that wrench only fits one way on
nut. Be sure wrench is fully engaged in nut slots and is not cocked.
(b) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel drive models, install Socket Wrench 6442 on main-
shaft splines. Then install breaker bar in socket wrench (Fig. 13). Wedge breaker bar handle
J9221-90
GEAR

Fig. 11 Removing Countershaft Fifth Gear Synchro Components against workbench. Purpose of socket wrench and
breaker bar is to prevent mainshaft from turning
while nut is loosened.
(c) Position small end of Nut Wrench 6443 at ap­
proximately 10 o'clock position (Fig. 12).
(d) Strike small end of Nut Wrench 6443 with
heavy copper hammer to break nut loose. Nut is se­
cured by interference fit thread plus Loctite adhe­ sive and will require several firm blows to loosen it
(nut torque is in 300 ft. lb. range). (e) Once nut is loose, it can be removed by hold­
ing nut wrench with breaker bar and rotating out­
put shaft with socket wrench and ratchet.
(f)
Remove fifth gear nut and coned washer from
shaft (Fig. 14). Note position of washer for assem­
bly reference (coned side of washer faces rear). SPECIAL
STRIKE
NUT J9221-91

Fig. 12 installing Nut Wrench On Mainshaft Fifth Gear

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21 - I

SPECIAL FIFTH
RATCHET
WRENCH J9221-92

Fig. 13 Removing Mainshaft Fifth Gear Nut From Shaft Threads

FIFTH
NUT
Fig. 14 Mainshaft Fifth Gear Nut And Washer Removal (5) Remove roll pins that secure countershaft fifth
gear shift fork to shift rail with pin punch (Fig. 10).
Roll pins are driven out from
bottom
of fork and
not from top.
(6) Remove fifth gear shift fork and sleeve as as­
sembly (Fig. 15). Remove fork by tapping it off rail
with plastic mallet. Leave sleeve engaged in fork or note position of sleeve for assembly refer­

ence.

(7) Remove countershaft fifth gear and hub assem­
bly (Fig. 16). (8) Remove countershaft fifth gear needle bearing
assemblies (Fig. 17). (9) Remove cone shaped rear bearing thrust
washer from end of countershaft (Fig. 18). Note posi­
tion of washer for assembly reference. Also note that
PLASTIC FIFTH

Fig. 15 Fifth Gear Shift Fork And Sleeve Removal
Fig. 16 Removing Countershaft Fifth Gear And Synchro Hub Assembly washer bore has notch for locating pin.
(10) Remove and retain thrust washer locating pin
from countershaft (Fig. 19). Fig. 17 Countershaft Fifth Gear Needle Bearing
Removal

21
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SPECIAL TOOL
6459
SPECIAL TOOLS

6444-3
(3
REQD.)

THRUST
WASHER PIN THRUST
WASHER
(CONE SHAPED)
J9221-98
J9221-100

Fig.
18 Countershaft Rear Bearing Thrust
Washer
Removal

(11) Remove mainshaft fifth gear with Puller Tool
Set 6444 as follows:
(a) Position first Puller Jaw 6459 on gear (Fig.

19).
nr m

Fig.
20 Seating Puller Flange In First Puller Jaw SPECIAL TOOL

6444-8

J9221-101

Fig.
21 Installing Retaining Collar
Over
Puller
Jaws
SPECIAL TOOL
6444-8

1 MAINSHAFT
J9221-99
Fig.
19 Installing First Puller Jaw On Mainshaft
Fifth

Gear

(b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 20).
(c) Slide assembled puller flange and rods onto
output shaft. Then seat flange in notch of puller
jaw (Fig. 20).
(d) Position second Puller Jaw 6459 on gear and
in notch of puller flange (Fig. 21). (e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 21). (f) Install Puller and Bolt 6444 on puller rods.
Then secure puller to rods with retaining nuts (Fig.
22).
SPECIAL TOOL

6459

SPECIAL TOOL
6444

MAINSHAFT SPECIAL TOOL
6444-3
HOLDING
WRENCH
J9221-190

Fig.
22
Removing
Fifth
Gear
From
Mainshaft
Splines

(g) Tighten puller bolt to remove gear from shaft
splines (Fig. 22).

•

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21 - 11 (12) Remove bolts attaching mainshaft rear bear­
ing plate to gear case and remove fifth gear, plate,
end play shims and bearing cup (Fig. 28), .
MAINSHAFT REAR

BEARING
CUP
BEARING

SHIMS
BEARING

PLATE
FIFTH GEAR

J9221-102

Fig.
23 Removing Mainshaft Fifth
Gear,
Bearing Plate, Bearing Shims And Rear Bearing Cup FRONT RETAINER REMOWAL AND
DISASSEMBLY (1) Remove front retainer bolts (Fig. 24).

FRONT
BEARING
RETAINER
J9221-103

Fig.
24
Removing
Front Bearing Retainer
Bolts

(2) Remove front retainer by lightly tapping it
back and forth with plastic mallet to loosen it. Then rock retainer back and forth by hand to work it out
of gear case. Note that retainer flange extends into and is fairly snug fit in case bore.
(3) Remove seal from front retainer (Fig. 25). Use
small chisel to collapse one side of seal then pry it
out with suitable tool.
(4) Remove bearing cup from front retainer as fol­

lows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 26).
(b) Insert Puller Jaws 6453-1 in puller flange
(Fig. 26). Narrow lip of puller jaws will go under
bearing cup.
(c) Install assembled tools in front retainer (Fig.

27).
Be sure puller jaws are seated under bearing cup.
(d) Place Insert Tool 6453-2 in center of puller
jaws (Fig. 27). Insert tool is used to hold puller
jaws in place.
FRONT
BEARING

RETAINER
SEAL

Fig.
25 Removing Bearing Retainer
Seal

SPECIAL
TOOL

6453-1
SPECIAL

TOOL

6444-4

SPECIAL
TOOL

6444-1

J9221-178X

Fig.
26
Assembling
Puller
Rods,
Flange And
Jaws
SPECIAL
TOOL

6453
SPECIAL

TOOL

6453-2

FRONT

RETAINER
J9221-179
Fig.
27 Installing Puller Tools In Front Retainer

21-12
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• (e) Install Puller 6444 on puller rods (Fig. 28).
Then install retaining nuts on puller rods. (f) Tighten puller bolt to draw bearing cup out of
retainer (Fig. 28). Use holding wrench on puller and turn puller bolt with adjustable wrench.
TIGHTENING

WRENCH
HOLDING

WRENCH

SPECIAL
TOOL

6453-2

FRONT

RETAINER
J922M80

Fig.
28
Removing
Bearing Cup From Front Retainer DRIVE GEAR REMOVAL AND DISASSEMBLY
(1) Remove drive gear. Tilt gear downward and out
of case (Fig. 29).
(2) Remove pilot bearing from drive gear (Fig. 30).
(3) Remove bearing from drive gear as follows:
J9221-105
DRIVE
GEAR

MAINSHAFT

PILOT
BEARING

J9221-106
Fig.
30 Pilot Bearing Removal/Installation
(a) Note that puller tool assembly and setup is
similar to that used for removing fifth gear from
mainshaft (Figs. 19-23). (b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-4. Then position first Puller Jaw 6447
on gear (Fig. 31).
(c) Slide assembled puller flange and rod tools
onto output shaft. Then seat flange in notch of
puller jaw (Fig. 31). (d) Position second Puller Jaw 6447 on gear and
in notch of puller flange (Fig. 31).
SPECIAL
TOOL

6444

DRIVE
GEAR

SPECIAL
TOOL

6444-1
SPECIAL

TOOLS

6444-6
(3)

SPECIAL
TOOLS
6447
(2)

Fig.
29 Drive Gear
Removal
SPECIAL
TOOL

6444-8

J9221-115X

Fig.
31
Removing
Front Bearing From Drive Gear

+

MAINSHAFT AND GEARTRAIN REMOVAL
(1) Remove countershaft rear bearing plate (Fig.

32).

Fig.
32
Removing
Countershaft Rear Bearing
Plate
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33).
Fig.
33 Countershaft End Play
Shim
And Rear

Bearing
Cup
Removal
(3) Remove reverse idler shaft. Thread a shift
cover bolt into shaft and withdraw shaft from case (Fig. 34).
(4) Move 1-2 and 3-4 synchro sleeves into Neutral,
if necessary.
(5)
Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 35).
(6) Remove fourth speed clutch gear and synchro
stop ring from mainshaft (Fig. 36).
N¥4S0O
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21 - 13

Fig.
34
Removing
Reverse
Idler Shaft

Fig.
35 Drive Gear Thrust Bearing
Removal

Fig.
36 Fourth
Speed
Clutch
Gear
Stop
Ring
Removal
(7) Roll gear case onto left side (Fig. 37).
(8) Reach into gear case and push reverse idler
gear away from mainshaft gears.
(9) Remove mainshaft assembly as follows (Fig.

37):
(a) Lift front end of mainshaft slightly.
(b) Grasp mainshaft rear splines. Then turn
spline end of mainshaft in counterclockwise direc­
tion to rotate shaft and geartrain out of case.
(c) Once mainshaft gears roll clear of counter­
shaft gears, shaft and gear assembly can be tilted
outward and removed from gear case (Fig. 37).
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 31).
(f) Install Puller 6444 on puller rods. Then se­
cure puller to rods with retaining nuts (Fig. 31).
(g) Tighten puller bolt to remove bearing cone
from drive gear (Fig. 31).

21
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Fig.
37 Mainshaft And
Geartrain
Removal
(10) Refer to mainshaft disassembly procedures if
any gears or synchro components must be replaced.

REVERSE IDLER GEAR
AMD
COUNTERSHAFT

REMOVAL/DISASSEMBL
¥
(1) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 38).

Fig.
38
idler
Gear
Moved
Away
From Countershaft (2) Remove idler gear through drive gear bore at
front of case (Fig. 39).
(3) Keep reverse idler gear bearings and spacer to­
gether for cleaning and inspection (Fig. 40). Insert
idler shaft through gear and bearings to keep them
in place.
(4) Remove idler gear thrust washers from gear

case.
Install washers on idler shaft to keep them to­
gether for cleaning and inspection.
(5) Remove countershaft rear bearing. Shaft can­
not be removed from case until rear bearing has been
removed. Bearing removal procedure is as follows: (a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 41). •
J922M14

Fig.
39
Reverse
Idler Gear
Removal
REVERSE

BEARINGS IDLER
Fig.
40
Reverse
Idler Gear
Components
(b) Position first Puller Jaw 6449 on bearing
cone (Fig. 41).
(c) Seat puller flange in notch of puller jaw just
installed on bearing cone (Fig. 41).
(d) Install second Puller Jaw 6449 on bearing
and in notch of puller flange (Fig. 41). (e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 41). Note that re­ taining collar has small lip on one end and only
fits one way over jaws.
Fig.
41
Removing
Countershaft Rear Bearing

•

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TRANSMISSION OVERHAUL
21 - 15 (f) Install Puller 6444 on puller rods. Then se­
cure puller to rods with retaining nuts (Fig. 41). (g) Tighten puller bolt to remove bearing from
shaft (Fig. 41). If bearing is exceptionally tight, tap
end of puller bolt with copper mallet to help loosen
bearing.
(6) Remove bearing puller tools.
(7) Rotate countershaft out of gear case (Fig. 42).
Fig.
42
Removing
Countershaft From Gear
Case

(8) Remove countershaft front bearing as follows:
(a) Assemble Puller Flange 6444-1 and Puller
Bolts 6444-6 (Fig. 43).
(b) Position first Puller Jaw 6451 on bearing. (c) Seat puller flange in notch of puller jaw.
(d) Install second Puller Jaw 6451 on bearing
and in notch of puller flange.
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 43). Note that re­ taining collar has small lip on one end and only
fits one way over jaws. (f) Install Puller Bridge And Bolt Assembly 6444
on puller bolts. Then secure bridge to bolts with re­
taining nuts (Fig. 43). J922M 59X
6444-4

Fig.
43
Removing
Countershaft Front Bearing (g) Tighten puller bolt to remove bearing from
shaft (Fig. 43). If bearing is exceptionally tight, tap
end of puller bolt with mallet to help loosen bear­ ing.
(9) Remove bearing puller tools.
(10) Set countershaft and idler gear aside for
cleaning and inspection.
GEAR CASE DISASSEMBL¥ (1) Remove countershaft front bearing cap. Use
mallet or hammer to remove cap from inside case (Fig. 44).
Fig.
44 Countershaft Front Bearing Cap
Removal

(2) Remove countershaft front bearing cup with
Remover Tool 6454 and Tool Handle C-4171 (Fig.

45).
Fig.
45 Countershaft Front Bearing Cup
Removal
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 46). A small pin punch can be mod­ ified by putting a slight bend in it to drive pin com­
pletely out of shift rail (Fig. 46).
(4) Remove shift lug rail by tapping it out of case
and shift lug with tapered punch (Fig. 47). Note po­
sition of rail and lug for assembly reference.
(5) Remove lug rail bushings from gear case with
Special Tool 6456 (Fig. 48).
(6) Unclip and remove magnet from bottom of gear
case (Fig. 49).