1993 DODGE TRUCK Service Repair Manual

21
- 48
G360
MANUAL
TRANSMISSION

J9121-257

Fig.
6 Removing/Installing
Lower
Boot
And
Plate
(6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).

Fig.
7 Removing/Installing Shift Tower
Boot

(7) Remove snap ring securing shift lever in shift
tower (Fig. 8).
(8) Remove shift lever (Fig. 10). If lever does not
come out readily, press lever downward and quickly
release it two or three times. Or lightly tap side of lever with plastic mallet to loosen it. Note align- •

Fig.
8
Removing
Shift
Lever
Snap
Ring
ment slots in lever color and pivot ball (Fig. 9).
These slots align with shoulder bolts in shift
tower.
Fig.
9 Removing/Installing Shift
Lever

(9) Raise and support vehicle.
(10) Mark propeller shaft U-joints and axle yokes
for assembly alignment reference (Fig. 10).
(11) Remove propeller shaft. Remove clamp strap
bolts at front of shaft first. Remove center bearing
bracket bolts and support shaft on tool box or stand. Then remove rear clamp strap bolts and remove shaft.
(12) Spread clamps that secure switch wires to
transmission top cover and remove wires from clamps. Move wires aside to protect them and pro­vide working clearance.

•
Fig. 11 Transmission Rear Mount Bolt Locations (14) Support transmission with transmission jack
(Fig. 12). Secure transmission to jack with safety
chains as shown.
(15) On some models it may be necessary to re­
move screws attaching fuel line clamps to driver side
frame rail (Fig. 13). Three clamps must be removed so fuel lines can be moved for access to crossmember
bolts on this side of frame rail.
(16) Remove left and right crossmember-to-frame
braces (Fig. 14) and remove crossmember.
G360 MANUAL
TRANSMISSION
21 - 49

Fig,
12 Transmission Supported On
Jack

Fig. 13 Removing/installing Fuel Line Clamps
SAFETY

21
- 50
G360
MANUAL
TRANSMISSION

•

FRAME RAIL
CROSSMEMBER
DRIVER SIDE

BRACKET
PASSENGER.

SIDE

BRACE
CROSSMEMBER

J9221-65
Fig.
14
Crossmember
And
Braces

(17) Remove clutch slave cylinder shield (Fig. 15).

SLAVE

CYLINDER
HEAT SHIELD

J9121-269

Fig.
15 Removing/Installing
Slave
Cylinder
Shield
(18) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever (Fig.
16).
This reduces pressure on lever and release bear­
ing making transmission removal/installation easier. Cylinder does not have to be removed completely.
SLAVE

CYLINDER PISTON ROD
CLUTCH

RELEASE
FORK
LOOSEN CYLINDER NUTS TO RELIEVE TENSION
ON FORK AND BEARING
J9121-270

Fig.
16
Loosening
Slave
Cylinder
Nuts

(19) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission slightly to help free input shaft from clutch disc and
release bearing.
(20) Support engine with wood block and adjust­
able jack stand (Fig. 17).

J9106-22

Fig.
17 Typical Method Of
Supporting
Engine

TRANSMISSION
INSTALLATION—2-WHEEL
DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains. (2) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of input shaft (Fig. 18) and following components:

CAUTION:
Do not use an
excessive
amount
of

grease. Excessive
amounts
of
grease
could
result
in
grease
contamination
of the
clutch
disc.

• input shaft splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bushing • release bearing bore
• release fork

•
• release fork ball stud
• propeller shaft slip yoke

APPLY
LIGHT
COAT
OF

HI-TEMP
GREASE
TO
THESE

SURFACES
BEFORE
INSTALLATION
J9106-15

Fig.
18 input Shaft Lubrication
Points
(Typical)
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re­ lease bearing and clutch disc hub. Rotate output
shaft with socket or yoke to align input shaft and
clutch disc splines if necessary.
(4) Move transmission forward and seat transmis­
sion against housing. (5) Install and tighten transmission mounting
bolts to 68 N-m (50 ft-lbs). (6) Install rear crossmember and crossmember
brackets. Start all crossmember bolts/nuts before
tightening to final torque of 68 N»m (50 ft-lbs). (7) Remove transmission jack.
(8) Install screws that attach fuel line clamps to
driver side frame rail. (9) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (10) Install clutch slave cylinder shield.
(11) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(12) Align and install propeller shaft. Support
shaft on box or stand. Install shaft front U-joint first.
Next, secure center bearing bracket to frame bracket.
Then install shaft rear U-joint in axle yoke. Final- tighten U-joint clamp bolts to 19 N@m (14 ft-lbs) and center bearing bracket bolts to 68 N»m (50 ft-lbs). (13) Lower vehicle.
(14) Lubricate shift lever ball and collar with Mo­
par all purpose grease. (15) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (16) Press shift lever and collar downward and in­
stall shift lever snap ring. (17) Tighten shift lever alignment bolts com­
pletely. (18) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (19) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large G360
MANUAL TRANSMISSION
21 - 51

SKID

PLATE
J9121-525

Fig.
19 Transfer
Case
Skid
Plate
Mounting
notch is forward then install lower boot attaching
screws. (20) Thread or bolt shift lever extension to shift le­
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws.
(21) Install shift knob on extension (if removed). (22) Connect battery negative cable.

TRANSMISSION REMOVAL—4-WHEEL DRIVE
(1) Disconnect battery negative cable.
(2) Remove screws attaching shift lever upper boot
to metal plate on lower boot. Then slide boot upward on lever (Fig. 3).
(3) Remove screws attaching lower boot and plate
assembly to floor pan (Fig. 4). (4) Remove shift lever extension by unthreading it
from shift lever (Fig. 5). (5) Slide lower boot and plate upward and off shift
lever (Fig. 6). (6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).

(7)
Remove snap ring securing shift lever in shift
tower (Fig. 8). (8) Remove shift lever (Fig. 9). If lever does not
come out readily, press lever downward and quickly
release it two or three times. Pressure from spring under lever should push it out of housing. Note alignment slots in lever cover and pivot ball
(Fig. 9). These slots align with shoulder bolts in
shift tower.
(9) Raise and support vehicle.
(10) Mark front and rear propeller shafts for in­
stallation reference (Fig. 10). Then disconnect and re­
move both shafts. (11) Remove transfer case skid plate and cross-
member (Fig. 19).

21 - 52 G360
MANUAL
TRANSMISSION

• (12) Disconnect wires at vehicle speed sensor and
backup light switch.
(13) Disconnect transfer case shift lever from lever
on transfer case.
(14) Temporarily support transmission with adjust­
able jack stand. Then support transfer case with
transmission jack.
(15) Remove nuts attaching transfer case to trans­
mission adapter and move transfer case away from
transmission rear retainer.
(16) Lower transfer case and move it from under
vehicle. Remove transfer case from transmission jack and place transfer case on workbench.
(17) Support transmission with transmission jack.
Secure transmission to jack with safety chains. Then
remove jack stand previously used to support trans­
mission.
(18) Spread clamps that secure switch wires to
transmission top cover and remove wires from clamps. Move wires aside to protect them and pro­
vide working clearance.
(19) Remove bolts attaching transmission rear
mount to crossmember.
(20) On some models, it is necessary to remove
screws attaching fuel line clamps to driver side
frame rail. Three clamps must be removed to so fuel lines can be moved for access to crossmember bolts at
this side of frame rail.
(21) Remove left and right crossmember-to-frame
braces and remove crossmember.
(22) Remove clutch slave cylinder shield.
(23) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever (Fig.

20).
This reduces pressure on lever and release bear­
ing making transmission removal/installation easier. Cylinder does not have to be removed completely.
(24) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission slightly to help free input shaft from clutch disc and
release bearing.
(25) Support engine with wood block and another
adjustable jack stand.

TRANSMISSION
INSTALLATION—4-WHEEL
DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains.
(2) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of input shaft (Fig. 20) and following components:

CAUTION:
Do not use
excessive
amounts
of
grease.

This
practice
could
result in contamination of the

clutch
disc.

• input shaft splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bushing
• release bearing bore
• release fork
• release fork ball stud • propeller shaft slip yoke
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re­ lease bearing and hub of clutch disc. (4) Rotate output shaft with socket or yoke to align
input shaft and clutch disc splines. If input shaft will
not rotate enough in neutral to align splines, it will
be necessary to shift transmission into third or fourth gear with screwdriver. (5) Seat transmission against clutch housing and
align bolt holes in transmission and housing. (6) Install and tighten transmission-to-clutch hous­
ing bolts to 68 N-m (50 ft. lbs.). (7) Install rear crossmember and mount. Start all
crossmember bolts/nuts then tighten them to 68 N*m (50 ft. lbs.) torque. (8) Remove transmission jack.
(9) Install screws that attach fuel line clamps to
driver side frame rail. (10) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (11) Install clutch slave cylinder shield.
(12) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(13) Install gasket and transfer case on transmis­
sion rear retainer. Tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque. (14) Check transmission and transfer case lubri­
cant levels. Add lubricant if necessary and install fill

plugs.

(15) Connect transfer case shift lever to lever on
transfer case.
(16) Align and install propeller shafts. Tighten
U-joint clamp bolts to 19 N-m (14 ft. lbs.). (17) Install skid plate and crossmember. Tighten
skid plate and crossmember bolts/nuts to 41 N—m
(30 ft. lbs.) torque.
(18) Lower vehicle.
(19) Shift transmission into neutral if necessary.
(20) Lubricate shift lever ball and collar with Mo­
par all purpose grease. (21) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (22) Press shift lever and collar downward and in­
stall shift lever snap ring. (23) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (24) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large
notch is forward then install lower boot attaching screws. (25) Thread or bolt shift lever extension to shift le­
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws. (26) Install shift knob on extension (if removed).
(27) Connect battery negative cable.

•

G360
TRANSMISSION OVERHAUL
21 - 53
G360
TRANSMISSION
OVERHAUL

INDEX

page

Transmission
Assembly
and
Adjustment
.......
63

Transmission
Cleaning
and
Inspection
59

TRANSMISSION
DISASSEMBLY

SHIFT COVER REMOVAL (1) Shift transmission into neutral.
(2) Remove shift cover bolts.
(3) Loosen shift cover with
two pry
tools. Insert
tools
in
cover slots
and pry
cover
off
alignment dow­ els
(Fig. 1). It is
important
to
remove
the
cover evenly
to
avoid damage.
Do not pry one
side
loose then
the
other. This practice could damage the forks
and
cover.

SHIFT

COVER

Fig.
1
Loosening
Shift
Cover

(4) Remove shift cover assembly
(Fig. 2).
Discard
old shift cover gasket. Note that
a
gasket
was not

used
on
early production transmissions.
It is

recommended that
a
gasket
be
used when shift
cover
is
installed after overhaul. (5)
Set
shift cover assembly aside
for
inspection.

REARING
RETAINER
AND
SHAFT BEARING

RACE
REMOVAL (1) Remove front bearing retainer bolts
and re­

move retainer
(Fig. 3). Tap
retainer with rubber mal­ let
to
loosen
it if
necessary.
(2)
On
2-wheel drive models, remove rear bearing
retainer
as
follows
(Fig. 4):
(a) Remove
nut
attaching yoke
to
output.
Torque
on nut is
quite high. Best
way to re­

move
nut is
with 350-400
ft. lb.
rated high
ca­

pacity impact wrench.
(b) Remove yoke from output shaft splines.
page

Transmission
Disassembly
53

Fig.
2
Shift
Cover
Removal/Installation

CHANNELS
(4)
J9321-268
Fig.
3
Front Bearing Retainer
Removal

(c) Remove bolts attaching rear bearing retainer
to gear case
and
remove retainer.
Use
rubber mal­ let
to
loosen retainer
if
necessary.
(d) Remove speedometer gear
and
spacers from
output shaft.
(e) Remove preload shims from rear retainer,
or

bearings.
(f) Remove yoke seal from retainer with suitable
pry tool.
Do not
damage retainer surface while
re­
moving seal.
(3)
On
4-wheel drive transmission, remove rear
bearing retainer bolts
and
remove retainer from gear case
(Fig. 5).

21
- 54
G350
TRANSMISSION
OVERHAUL

4-
REAR

BEARING

RETAINER

SPEEDOMETER
GEAR
>YOKE

NUT

YOKE

SPACERS
YOKE

SEAL

J9321-271

Fig.
4 Two Wheel Drive Rear Bearing Retainer And Speedometer Gear
Removal

(4)
On 4-wheel drive transmission, remove bearing
OUTPUT

preload shims from rear bearing retainer (Fig. 6). On
SHAFT
2-wheel
drive transmissions, remove shims from re-
SHIM

tainer and slide output shaft rear bearing shims off \, shaft.
REAR

BEARING

RETAINER
J9321-270

Fig.
6
Shim
Locations In Rear Bearing Retainer
(5)
Remove output shaft and countershaft bearing
races (Fig. 7). Tap front and rear faces of gear case
with large plastic mallet to loosen and remove races. Do not strike bearing races. Tap on case sur­
faces only.
J9321-267

Fig.
5
Four
Wheel Drive Rear Bearing Retainer
Removal

•

G360
TRANSMISSION
OVERHAUL
21 - ii
Fig. 7 Shaft Bearing Race Removal
INPUT
SHAFT
AND OUTPUT
SHAFT REMOWAL
(1)
Rotate input shaft until flats on shaft clutch
teeth are facing downward toward countershaft (Fig.

8).
Fig. 8 Location Of Input Shaft Clutch Gear Flats

(2)
Work input shaft forward until clear of output
shaft.

(3)
Remove output shaft and gears as assembly
from case (Fig. 9).
(4)
Remove input shaft from case (Fig. 9).

(5)
If bearing on input shaft is damaged, press
bearing from shaft. Use hydraulic shop press and standard bearing splitter type remover tool. Fig. 9 Output Shaft And Gear Assembly Removal

COUNTER GEAR
AND
SHAFT REMOWAL
(1)
Remove countershaft front bearing cap from
case (Fig. 10). Strike cap with punch to unseat it. Ex­
ercise care as bearing could be damaged if punch
penetrates cap and contacts bearing.
(2)
Remove large snap ring retaining counter gear
shaft front bearing race in gear case (Fig. 10).

(3)
Remove counter gear shaft front bearing race
from gear case (Fig. 10). If race proves difficult to re­ move, use a slide hammer and blind hole puller tool. Or, remove rear bearing snap ring and drive counter
gear shaft (and front bearing) out front of case. Pro­
cedure is outlined in following steps.
BEARING

CAP
J9321-274

Fig. 10 Counter Gear Shaft Front Bearing Cap, Snap Ring And Race Removal
(4)
Remove small snap ring retaining rear bearing
on counter gear shaft (Fig. 11).