1993 DODGE TRUCK Service Repair Manual

21
-
56
G360
TRANSMISSION OVERHAUL
^ ^ ^ ^ •

REAR

BEARING
SNAP

RING COUNTER

GEAR

SHAFT

REAR

BEARING

J9321-275

Fig.
11
Removing
Counter
Gear Shaft Front Bearing
Snap
Ring

(5) Tap countershaft out of forward end of gear
case (Fig. 12). Use hammer and brass punch to re­
move shaft and front bearing.

(6)
If countershaft rear bearing is damaged, re­
move snap ring and press bearing off shaft.
COUNTER

GEAR

SHAFT
AND

FRONT
BEARING
J9321-276

Fig.
12
Counter
Gear Shaft And Front Bearing
Removal

(7) Position gear case in upright position (Fig. 13).
(8) Remove counter gear from case as follows: (a) On transmission with new style gear case,
counter gear can be removed by rotating it past re­
verse idler gear and out of case (Fig. 13).
(b) On transmission with early style gear
case, it will be necessary to remove reverse
idler gear before counter gear can be removed. Refer to following Reverse Idler Gear Removal
procedures.
REVERSE IDLER GEAR REMOVAL Two styles of transmission case were used for the
G360 transmission. Early style cases had a partial
radius machined in the reverse idler area while later style cases had a full radius. The different machining
required different methods for removing the reverse idler gear and shaft.
On early style gear cases, the idler gear must be
removed before the counter gear can be removed.
On new style cases, the counter gear can be re­
moved with the idler gear still in place.
REVERSE
IDLER

GEAR
ROTATE

COUNTER
GEAR
PAST
IDLER

GEAR
AND
OUT OF
CASE
J9321-277

Fig.
13
Counter
Gear
Removal
(With
New Style Gear
Case)

Reverse
Idler
Removal (New Style Gear Case)
(1) Remove idler shaft pins (Fig. 14). Use appropri­
ate size pin punch only to remove pins. Discard pins
after removal as they are not reusable.

IDLER

GEAR
PINS

(REMOVE
WITH

PIN
PUNCH
ONLY)

REVERSE IDLER

GEAR
J9321-279

Fig.
14 Location Of
Reverse
Idler Shaft
Pins

(2) Remove bolt that aligns and secures idler shaft
in case (Fig. 15). Keep bolt with idler gear compo­

nents.
Do not intermix it with other fasteners.

G350 TRANSMISSION OVERHAUL
21 - 57

REVERSE
IDLER

SHAFT
BOLT

J9321-278
Fig.
15
Reverse
idler
Shaft
-Bolt
Removal

(3) Remove reverse idler shaft (Fig. 16)

REVERSE
IDLER

SHAFT
J9321-280

Fig.
16
Reverse
Idler Shaft
Removal
(New Style
Gear
Case)

(4) Remove idler gear, thrust washers, bearings
and spacer as assembly (Fig. 17).

IDLER
GEAR
THRUST

WASHERS
J9321-281

Fig.
17
Reverse
Idler Gear
Removal
(New Style Gear

Case)

Reverse
Idler
Removal (Early Style Gear
Case)
(1) Remove front pin from idler shaft first. (2) Slide gear and washer forward and remove rear
pin.
(3) Remove bolt securing idler shaft in case.
(4) Slide idler shaft forward and remove gear and
washer from case. Turn counter gear to help rotate idler gear out of case.

OUTPUT
SHAFT DISASSEMBLY
Do not disassemble the 1-2, 3-4 and fifth-re­
verse synchros during overhaul. The component
parts in each synchro are not available sepa­
rately. The synchros are serviced as assemblies only.

CAUTION:
The
output shaft
and
geartrain
are
quite heavy. Have
a
helper support
and
hold
the
output
shaft
and
gear assembly during
all
press opera­

tions.
Do not
allow
the
shaft
and
gear assembly
to

fall
and
strike
the
shop floor.

(1) Press fifth gear and rear bearing off output
shaft. Use standard bearing splitter type remover
tool and shop press to remove gear and bearing (Fig.
18).

REAR

BEARING

STANDARD
TYPE
REMOVER
TOOL

PRESS
RAM
OUTPUT

SHAFT

Fig.
18
Removing
Fifth
Gear And Rear Bearing (2) Remove fifth-reverse snap ring and blocker
ring (Fig. 19). (3) Remove two halves of fifth gear bearing from
output shaft (Fig. 20).

21
- 58
G360
TRANSMISSION
OVERHAUL

•

SNAP
RING
BLOCKER

RING
FIFTH-REVERSE
SYNCHRO

ASSEMBLY
J9321-283

Fig.
19
Removing
Fifth-Reverse
Snap Ring
And
Blocker Ring
(4) Remove reverse gear and fifth-reverse synchro
assembly (Fig. 20). Use two large, flat-blade screw­
drivers to pry components up and off mainshaft splines (Fig. 20). If gear and synchro proves difficult
to remove, use a press and bearing splitter for re­
moval.
(5) Remove reverse gear bearing from gear or out­
put shaft.

FIFTH

GEAR

BEARING
(2-PIECE) FIFTH-REVERSE

SYNCHRO

ASSEMBLY
REVERSE

GEAR
PRY>
TOOLS
J9321-284

Fig.
20
Reverse
Gear And Fifth-Reverse
Synchro
Removal

(6) Remove first gear snap ring (Fig. 21).
(7) Remove first gear (Fig. 22). Use shop press and
two press plates to press gear off shaft. Have helper
hold output shaft while removing gear.
(8) Remove first gear bearing from gear or output
shaft. (9) Mark position of 1-2 synchro assembly for in­
stallation reference. Then remove synchro assembly
from output shaft (Fig. 23).
(10) Remove pilot bearing, 3-4 synchro assembly
and third gear as a unit. Use suitable size bearing
splitter type remover tool, press tool and hydraulic
SNAP

RING
FIRST

GEAR
SNAP

RING

PLIERS

J9321-285

Fig.
21 First Gear
Snap Ring
Removal
PRESS
RAM
FIRST

GEAR
PRESS

PLATES

J9321-286

Fig.
22 First Gear
Removal
1-2

SYNCHRO

ASSEMBLY

(NOTE POSITION

BEFORE
REMOVAL)

J9321-288

Fig.
23
Removing
1-2
Synchro Assembly

shop press to remove these components (Fig. 24). Po­
sition remover tool jaws under third gear for re­
moval purposes. Also have helper support and
hold assembly during removal.

•

Fig.
24 Pilot Bearing, 3-4
Synchro
And Third Gear
Removal

THRUST

WASHER
J9321-290

Fig.
25
Second
Gear
Snap
Ring
Removal

(11) Remove third gear bearing from gear or shaft.
(12) Remove second gear snap ring with heavy
duty snap ring pliers (Fig. 25). Discard snap ring af­
ter removal as it is not reusable. (13) Remove second gear and thrust washer from
shaft with hydraulic shop press (Fig. 26). Have
helper hold output shaft while gear and washer are
being removed.
(14) Remove second gear bearing from gear or
shaft.

FIRST
AND SECOND GEAR BLOCKER RING
REMOVAL The blocker rings on the first and second gears are
secured to the gear with roll pins. The pins can either be removed completely, or sim­
ply tapped inward to allow blocker ring removal. An appropriate size pin punch and hammer, or locking
pliers are the only tools required for removal (Fig.
27).
Procedure is as follows:
G360
TRANSMISSION
OVERHAUL
21 - 59

Fig.
26
Second
Gear And Thrust
Washer
Removal
(1) On first gear, tap pins through blocker ring
and remove ring from gear.
(2) On second gear, remove blocker ring as follows: (a) Position gear on workbench so first roll pin to
be removed extends over edge of bench (Fig. 27). (b) Tap each roll pin about three quarters of way
through blocker ring. (c) Pry blocker ring off gear (Fig. 28). Discard
ring if considerable force was required to remove
ring from gear.
(d) Remove pins from gear with locking pliers
(Fig. 29).
(3) Discard roll pins after removal. They should
not be reused. (4) Discard either gear if damaged.

Fig.
27 Unseating
Blocker
Ring
Roll
Pins

TRANSMISSION
CLEANING
AND
INSPECTION
Clean the transmission components with solvent.
Use shop towels to dry bearings and bearing races. Compressed air can be used to dry the other trans­
mission components. Do not use compressed air to dry the bearings.
This practice can result in abrading and brinnel-
ling the bearing rollers and races.

21
- 60
G360
TRANSMISSION OVERHAUL

•
BLOCKER

Fig.
28
Removing
Blocker
Ring
From Gear
Output Shaft And
Gears
Inspect the shaft and gears for wear, or damage
(Fig. 30). Check for broken, or chipped gear teeth, SECOND
GEAR

Fig.
29
Removing
Roll
Pins
From Gear damaged synchro blocker rings, or worn galled bear­

ings.
Discoloration or shiny spots on gear teeth are a normal condition and do not indicate a need for re­
placement.
1 I

21 - 62 G360
TRANSMISSION
OVERHAUL

Synchronizers
And
Blocker
Rings

LEGEND
FOR OUTPUT SHAFT AND GEARTRAIN
COUNTER

GEAR

8

9

ho
11
12
13 14
15
16
17
18
19
20'
21
22

23'

24
25
'26 27
28
29 Front
Bearing

Input
Shaft

Blocker
Ring
(4th Gear)
Output
Shan
Pilot
Bearing

3-4
Synchro
Assembly
Blocker
Ring
(3rd gear)
Third
Gear

Third
Gear
Bearing
Snap
Ring

Spacer

Second
Gear

Second
Gear
Blocker
Ring
And Retaining
Pins
(3)

Second
Gear
Bearing

Output
Shaft
(2WD
version
shown)

1
-2
Synchro
Assembly

First
Gear
Bearing

First
Blocker
Ring
And Retaining
Pins
(3)

First
Gear

Spacer

Snap
Ring

Reverse
Gear
Bearing

Reverse
Gear

Blocker
Ring
(reverse gear)

Fifth-Reverse
Synchro
Assembly

Snap
Ring

Fifth
Gear
Bearing
(2-piece)

Blocker
Ring
(fifth
gear)

Fifth
Gear

Rear
Bearing
J9321-305

Inspect the synchro blocker rings (Fig. 30). Look
for evidence of wear or damage to the clutch material
on the rings. Also check the rings for cracks. Place
the rings on a flat surface to check for distortion.
The 1-2, 3-4 and fifth-reverse synchro hubs,
sleeves, struts and springs are serviced as assem­

blies.
If wear or damage is evident, it will be neces­ sary to replace the complete synchro assembly.

Counter
Gear
And Shaft Check the gear, shaft and bearings for wear or
damage (Fig. 31). Minor nicks or scratches on the
gear teeth can be smoothed off with an oilstone. Mi­
nor nicks or scratches on the shaft can be reduced and smoothed off with 320/400 grit emery cloth. The counter gear and shaft are not serviceable
components. If either part is damaged, it will be nec­
essary to replace the complete transmission assem­
bly.

Reverse
Idler
Components The reverse idler components consist of the gear,
shaft, thrust washers, pins, bearings and the shaft
bolt (Fig. 32). Clean and inspect the idler components. Replace
the gear if any teeth are chipped, or cracked. Replace
the shaft and bearings if galled, brinnelled, or se­
verely worn. The thrust washers can be reused but only if wear is not excessive and the washer notches are in good condition.
Replace the pins during overhaul. The pins should
not be reused. Also be sure the shaft bolt and case
REAR

BEARING

AND
SNAP
RING

COUNTER
GEAR

SHAFT

FRONT

BEARING
AND

SNAP
RING
J9321-308

Fig.
31
Counter
Gear
Components
threads are in good condition. The case threads can
be cleaned up with a tap, or repaired with Heli-Coil stainless steel thread inserts if necessary. Replace
the bolt if damaged.

THRUST

WASHER
REVERSE

IDLER

GEAR
BEARINGS

IDLER

SHAFT SHAFT

BOLT
THRUST

WASHER

SHAFT
PINS

J9321-309

Fig.
32 Idler Gear
Components

Bearings
And
Races
Inspect each bearing and race carefully. Check for
such conditions as spalling, wear, cracks, distortion,
or flat spotting of the rollers and races. Replace any
bearing or race if doubt exists about its condition.

Seals
And
Snap
Rings
Replace front and rear retainer seals and the coun­
tershaft front bearing cap. Do not reuse these parts.

•
G360
TRANSMISSION
OVERHAUL
21 - 63 The retainer seals have a small spring around the in­
ner part of the seal. Be sure each seal is installed
with this spring facing the case interior.
The snap rings should all be replaced. Eeusing
snap rings is not recommended.

Shift
Cover
Inspect the shift cover components (Fig. 33). The
only serviceable shift cover components are the shift
lever, lever retainer ring, snap ring, boot and clamp, and backup light switch.
If any of the shift forks, shift rails, or shift rail de­
tent parts are worn, or damaged, replace the shift cover assembly.
COVER 1-2 3-4

SHIFT

RAILS
J9321-310

Fig.
33 Shift
Cover
Assembly

TRANSMISSION
ASSEMBLY
AND
ADJUSTMENT

Assembly
Information
The only gasket in current G360 transmissions is
the shift cover gasket. All other sealing surfaces are
to be sealed with a coating of Mopar Gasket Maker, or Loctite 518.
Prior production G360 transmissions with the
early style gear case, were not equipped with a shift cover gasket. It is recommended that a gas­
ket be used on these transmissions during over­
haul or whenever the shift cover is removed during service. A gasket is available separately
or as part of the basic overhaul kit.
Apply Mopar Lock N' Seal, or Loctite 242 to bolt
threads before installation. These products will en­ sure proper fastener retention and sealing.
Lubricate the transmission components with Mopar
5W-30 engine oil or equivalent, during assembly. Pe­ troleum jelly can be used to hold parts in place and
prelubricate bearings and seal lips.
Do not use chassis grease, or similar products
on any component during assembly. Heavy lu­
bricating grease will plug the transmission oil
passages resulting in failure. Preload adjustments are required for the output
shaft and countershaft bearings. Preload is accom­
plished by the use of select fit shims. An accurate
vernier style depth gauge, depth micrometer, or dial indicator and suitable mounting stand are required
for measurement and adjustment. The procedure is described in the Bearing Preload Adjustment section.
ASSEMBLING OUTPUT SHAFT AND
GEARTRAIN

(1) Lubricate mainshaft, gears and synchro compo­
nents with Mopar 5W-30 engine oil. (2) Install blocker rings on first and second gears
as follows:
(a) Start roll pins into blocker rings and gears
with hammer (Fig. 34). (b) Seat roll pins with pin punch (Fig. 35). Be
sure roll pins are seated flush with surface of each
blocker ring. Do not drive pins below surface of
rings.

Fig.
34 Starting
Roll
Pins
In
First/Second
Gear
Blocker
Rings

(3) Install bearing in second gear and install sec­
ond gear on output shaft (Fig. 36).
(4) Install second gear thrust washer on output
shaft (Fig. 37). Washer is tight fit on shaft. Heat
washer in oven or use suitable tool to seat
washer on shaft.If washer is heated to ease instal­
lation, heat washer for no more than 5 minutes at

200°F.