1993 DODGE TRUCK Service Repair Manual

21
- 64 1360
TRANSMISSION OVERHAUL

•

BLOCKER
RING

GEAR

J9321-297

Fig.
35 Seating
Roil
Pins
in
First/Second
Gear
Blocker
Rings

OUTPUT SHAFT-

SECOND
GEAR

J9321-298

Fig.
36
Second
Gear
Installation

INSTALLER
TOOL
THRUST

WASHER

SECOND
GEAR

J9321-299
Fig.
37
Second
Gear Thrust
Washer
Installation

(5)
Install second gear snap ring (Fig. 38). Snap
ring is select fit
part.
Use thickest snap ring that will fit

(6)
Install bearing in third gear. Then install gear
on output shaft (Fig. 39).
(7) Install synchro ring in third gear (Fig. 39).

(8)
Install 3-4 synchro assembly on output shaft
(Fig. 40). Side of synchro hub with long shoulder
goes to front of shaft and fits inside third gear.
Use suitable size pipe style tool to tap or press syn­
chro assembly into place.
SELECT

FIT

SNAP RING SECOND
GEAR

THRUST

WASHER

J9321-300
Fig.
38
Second
Gear
Snap
Ring
Installation

BLOCKER RING
THIRD

GEAR

J9321-301
Fig.
39 Third Gear And
Blocker
Ring
Installation

CAUTION:
Be
sure
the
third
gear blocker ring
is

aligned
with
the
synchro
hub
before seating
the
synchro
assembly. Failure
to
align
the
ring could result
in
damage
to the
blocker ring.
THIRD
GEAR
BLOCKER RING SYNCHRO
-INSTALLER
TOOL

3-4
SYNCHRO
ASSEMBLY

J9321-302

Fig.
40 Installing 3-4
Synchro
Assembly
(9)
Install pilot bearing on output shaft (Fig. 41).
Heat bearing in oven to ease installation, or use suit­ able tool to tap bearing into place.

(10)
Turn output shaft over so rear of shaft is fac­
ing upward.
(11)
Install 1-2 synchro assembly (Fig. 42). If new
synchro is being installed, it can be installed ei-

•

OUTPUT

SHAFT

"
PILOT
BEARING

J9321-303
Fig.
41 Output Shaft Pilot Bearing
Installation

ther way on shaft. If original synchro is being
reused, install synchro in same position as when
removed.

Fig.
42 Installing 1-2
Synchro
Assembly

(12) Install first gear bearing on mainshaft (Fig.

43). FIRST
GEAR
BEARING

J9321-306
Fig.
43 First Gear Bearing
Installation
G360
TRANSMISSION OVERHAUL
21 - 65
(13) Install first gear on mainshaft (Fig. 44). Work
gear back and forth until blocker ring seats in syn­
chro assembly.
Fig.
44 First Gear
Installation

(14) Install first gear thrust washer (Fig. 45).
Washer is tight fit on shaft. Either heat washer
in oven to ease installation, or use pipe tool or
brass drift to press washer onto shaft and against gear.
FIRST

GEAR Fig.
45 First Gear Thrust
Washer
Installation

(15) Install first gear snap ring (Fig. 46). Do not
overspread snap ring to install it. Also be sure snap ring is fully seated in shaft groove. Tap ring
into place with punch if necessary.
(16) Install bearing in reverse gear.
(17) Install reverse gear on mainshaft (Fig. 47).
(18) Install blocker ring in reverse gear (Fig. 47). (19) Install fifth-reverse synchro assembly (Fig.

48).
Be sure reverse gear blocker ring is aligned in synchro before proceeding. Use pipe tool to press syn­
chro into place if necessary.

21
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G360
TRANSMISSION
OVERHAUL

SELECT

Fig.
46 Installing First Gear
Snap Ring
BLOCKER

Fig.
47
Reverse
Gear And
Blocker Ring
Installation

J9321-314
Fig.
48 Fifth-Reverse
Synchro
Installation (20) Install fifth-reverse synchro snap ring (Fig.

49).
This is a select fit snap ring. Use thickest snap ring that will fit In shaft groove and be sure snap ring is fully seated in shaft groove.
Move synchro into reverse position for snap ring se­ lection if necessary.

Fig.
49 Fifth-Reverse
Synchro Snap Ring
Installation
(21) Install fifth gear bearing halves on output
shaft (Fig. 50). Use petroleum jelly to hold bearing
halves in place. (22) Install blocker ring in fifth-reverse synchro
sleeve (Fig. 50). (23) Install fifth gear (Fig. 50).
SYNCHRO
SLEEVE
J9321-316

Fig.
50
Fifth
Gear,
Bearings
And
Blocker Ring
Installation (24) Install rear bearing on output shaft (Fig. 51).
Use suitable tool to seat bearing on shaft. (25) Verify correct gear installation. Refer to in­
stallation sequence shown in Figure 51.

6360
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OVERHAUL
21 - 67

3-4
THIRD
1-2
SYNCHRO
REVERSE
FIFTH

SYNCHRO
GEAR
ASSEMBLY
GEAR GEAR

SECOND
FIRST
FIFTH-REVERSE
GEAR GEAR
SYNCHRO
ASSEMBLY
J9321-287

Fig.
51 Output Shaft
Gea
REVERSE IDLER GEAR INSTALLATION
Different procedures are required for installing the
idler gear in early and new style gear cases.
The idler gear can be installed before installing the
counter gear in a new style gear case. However, the
counter gear must be installed before the idler gear
in an early style gear case.
Refer to the appropriate idler gear installation pro­
cedure during reassembly.

Reverse
Idler Installation (With New
Style
Gear
Case)
(1) Install reverse idler shaft part way into case
(Fig. 52).
Fig.
52 Idler Shaft Installed
Part
Way In
Case
fin
Installation
Sequence
(3) Position thrust washer at each end of idler gear
and install gear assembly in case (Fig. 53). Be sure
slots in thrust washers face outward as idler
gear roll pins fit in these slots.
(4) Align idler shaft pin holes and push idler shaft
into place in gear and washers.

IDLER
GEAR

Fig.
53 Idler Gear And Thrust
Washer
Installation
(5) Partially install idler shaft pins. Insert pins
only far enough to hold thrust washers in place. (6) Check idler gear thrust washer clearance (Fig.
54) as follows:
(a) Check clearance between each thrust washer
and idler gear with feeler gauge. (b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.). (2) Install bearings and spacer in reverse idler
gear (Fig. 32). Be sure spacer is installed between
bearings.

21
- 68
G360
TRANSMISSION OVERHAUL

• (c) If clearance is not within specified limits, re­
move idler gear and replace thrust washers. Use
new pins when gear and washers are reinstalled.

THRUST

WASHER
INSERT FEELER GAUGE HERE TO CHECK
CLEARANCE
Fig.
54
Checking
Idler Gear Thrust
Washer
Clearance
(7) Install idler shaft bolt (Fig. 55). Tighten bolt to
54 N*m (40 ft. lbs.) torque. J9321-317

Fig.
55 Idler Shaft
Bolt
Installation

(8) Tap idler shaft pins into place (Fig. 56).
J9321-318

Fig.
56 Idler Shaft Pin
Installation
REVERSE IDLER INSTALLATION (WITH
EARLY STYLE GEAR CASE)
(1) Install counter gear and shaft in case. Refer to
procedure in this section.
(2) Install idler shaft part way into case from
front. (3) Assemble and install reverse idler gear and
thrust washers. (4) Install rear pin in idler gear and shaft. Then
install front pin. (5) Check idler gear thrust washer clearance (Fig.
54) as follows:
(a) Check clearance between each thrust washer
and idler gear with feeler gauge.
(b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.).
(6) If clearance is not within specified limits, re­
move idler gear and replace thrust washers. Use new
pins when gear and washers are reinstalled.
COUNTER GEAR AND SHAFT INSTALLATION (1) Place gear case in upright position. Front bear­
ing retainer/input shaft bore should be facing up
(Fig. 57). (2) Slide counter gear into position in case (Fig.

57).

(3) Install front bearing and bearing snap ring on
countershaft (Fig. 57).
(4) Install countershaft in gear and seat shaft front
bearing in case (Fig. 57).
FRONT

BEARING COUNTERSHAFT
COUNTER GEAR

J9321-319
Fig.
57 Countershaft And Gear
Installation

(5) Install countershaft front bearing race in case
and on bearing (Fig. 58).

•

G360
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21 - 69

Fig.
58 Countershaft Front Bearing
Race
Installation
(6)
Install snap ring that retains countershaft front
bearing race in case bore (Fig. 59).
Fig.
59 Front Bearing
Race
Snap
Ring
Installation

(7) Install countershaft front bearing cap in case
bore (Fig. 60). Apply Mopar adhesive/sealant, or 3M industrial sealant
#800
around outer edge of
bearing cap before installation.

Fig.
60 Countershaft Front Bearing Cap
Installation
(8) Install rear bearing on countershaft. Then in­
stall bearing retaining snap ring.

OUTPUT
AND
INPUT
SHAFT
INSTALLATION
(1) Install new seal in front bearing retainer (Fig.

61).
Use socket or pipe tool to seat seal in retainer.
Be sure seal lip faces inward toward case inte­
rior.
(2) Install new front bearing on input shaft if nec­
essary. Use shop press to install bearing.
USE
SOCKET

AS
INSTALLER
TOOL

SEAL
SEATED
IN
RETAINER RETAINER
J9321-327

Fig.
61 Input Shaft
Seal
Installation

(3) Install input shaft. Rotate shaft so flats on
clutch teeth are facing downward. Then install shaft
in case.
(4) Install output shaft and geartrain assembly in
case (Fig. 62).

Fig.
62 Output Shaft And
Geartrain
Assembly
Installation

(5) Install front bearing race in gear case.
(6) Apply recommended sealer to front bearing re­
tainer flange surface. Then apply oil to lip of retainer
oil seal.
(7) Install front bearing retainer on case (Fig. 63).
It is not necessary to align retainer in any spe­ cial position. Oil channels and bolt holes in re­
tainer are symmetrical and can be installed in any position.
(8) Apply Mopar Lock N' Seal or Loctite 242 to
front bearing retainer bolts. Then install and tighten
bolts to 22-30 N«m (16-22 ft. lbs.) torque.
(9) Before proceeding, verify that countershaft
front bearing cap has been installed (Fig. 64).

21
- 70
G360
TRANSMISSION OVERHAUL

•

Fig.
63 Front Bearing Retainer
installation
(10) Install output shaft rear bearing race. Tap
race into
position
with plastic mallet. (11) Install countershaft rear bearing race in case
(Fig. 64). Then position race on bearing and tap race
into position with plastic mallet.

Fig.
64 Countershaft Rear Bearing
Race
Position
OUTPUT SHAFT AND COUNTERSHAFT
BEARING PRELOAD ADJUSTMENT
Bearing preload adjustment is accomplished by the
use of shims. The shims are installed in the shim
bores machined into the rear retainer. (1) Place transmission in upright position. Use
wood blocks to support transmission on either side of
front bearing retainer.
(2) Tap output shaft and countershaft rear bearing
races into place. Be sure races are seated on bear­

ings.

(3) Measure distance from top each of rear bearing
race to case surface with depth gauge (Figs. 65 and
66).
Measurements reflect amount of bearing race
that extends above rear surface of case. Record these measurements as they will be needed for shim selec­
tion.
Fig.
65
Measuring
Height Of Output Shaft Rear

Bearing
Race
Fig.
66
Measuring
Height Of Countershaft Rear

Bearing
Race

(4) Measure depth of shim bore in rear retainer
with depth gauge (Figs. 67 and 68). Record this mea­ surement also as it will be needed for shim selection.
Fig.
67
Measuring
Depth Of Output Shaft Bearing

Shim
Bore
(In Rear
Retainer)

•

G360
TRANSMISSION OVERHAUL
21 - 71
DEPTH
GAUGE
REAR
RETAINER COUNTERSHAFT
BEARING SHIM
BORE

J9321-332

Fig.
68
Measuring
Depth Of Countershaft Bearing
Shim
Bore
(in Rear
Retainer)
(5) Select preload shims for shaft bearings as fol­

lows:
Subtract height of bearing from depth of shim

bore.
Then add extra shim thickness of 0.15 - 0.20 mm ( 0.006 - 0.008 in.) for correct preload.
(6) Assemble and install shim packs in rear re­
tainer (Fig. 69). Use petroleum jelly to hold shim
packs in place during installation. Position thin shims at rear of pack where they will seat in
rear retainer shim bore.
TRANSMISSION FINAL ASSEMBLY (1) Apply Mopar Gasket Maker, or Loctite 518 to
rear retainer flange surface. OUTPUT
SHAFT
BEARING SHIMS
COUNTERSHAFT BEARING SHIMS REAR
RETAINER

J9321-325

Fig.
69 Preload
Shim
Location (2) On 2-wheel drive transmissions, install new
output shaft seal in retainer. Then install speedome­
ter gear and spacers on output shaft (Fig. 70).
(3) Install rear retainer on gear case. Do not dis­
place preload shims when installing retainer. (4) Apply Mopar or Loctite thread locker to rear
retainer bolts. Then install and tighten bolts to 22-30 N-m (16-22 ft. lbs.) torque.
(5) On 2-wheel drive transmissions, lube propeller
shaft yoke seal surface with petroleum jelly or en­
gine oil and install yoke. Then install and tighten
new yoke nut to 380 N*m (280 ft. lbs.) torque.
(6) Apply coat of Mopar Perfect Seal, or similar
sealer to new shift cover gasket. Then position gas­
ket on gear case. (Although early production trans- REAR
BEARING
RETAINER
SPEEDOMETER GEAR YOKE
NUT
YOKE
SPACERS

Fig.
70 Two
Wheel
Drive Rear Bearing Retainer And Speedometer Gear
J9321-271