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2. Install input shaft retainer (1) and tighten bolts (2)
to 23 Nꞏm (17 ft. lbs.).
3. Install select end play shims into the countershaft
bearing cup bore.
4. Install countershaft bearing cup with Installer 9589
(1) and Handle C-4171 (2).
5. Install input shaft bearing oil supply washer and
select end play shims into mainshaft bearing cup
bore.
6. Install mainshaft bearing cup with Installer 9588 (1)
and Handle C-4171 (2).
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7. Apply Mopar™ Gasket Maker to the rear housing
sealing surface.
8. Install front housing (1) onto the rear housing (2).
9. Install housing bolts and tighten to 58 Nꞏm (43 ft.
lbs.).
10. Install 5-6 shift fork pins (1) into housing and
tighten to 58 Nꞏm (43 ft. lbs.).
11. Push shift tower boot (1) onto shift tower (2).
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12. Remove shift fork tie strap.
13. Apply Mopar™ Gasket Maker to the shift tower
opening.
14. Install shift tower (2) and tighten bolts (1) to 23
Nꞏm (17 ft. lbs.).
15. Install back up lamp switch (1) and bolt (2).
INSTALLATION
1. Clean transmission front housing mounting surface.
2. Apply light coat of Mopar high temperature bearing
grease or equivalent to contact surfaces of follow-
ing components:
release fork (1) ball stud (2)
release bearing slide surface (3)
input shaft splines (4)
release bearing bore (5)
propeller shaft slip yoke.
Page 2580 of 5267

3. Support and secure transmission to jack.
4. Raise and align transmission input shaft with clutch
disc, then slide transmission into place.
5. Install exhaust bracket diesel engine.
6. Verify front housing is fully seated.
Diesel Engine: Install transmission bolts (1,2)
and tighten to 41 Nꞏm (30 ft. lbs.). Tighten the
bolts with washers (2) into the transmission to 68
Nꞏm (50 ft. lbs.).
5.7 L Engine: Install transmission top four 3/8
bolts and tighten to 41 Nꞏm (30 ft. lbs.).
CAUTION: 5.7 L transmission bolts must be
installed in the followingorder. Failure to follow
these instructions will stress the engine and trans-
mission.
7. Install 5.7 L front dust shield bolts (3) and tighten to
54 Nꞏm (40 ft. lbs.). On 5.7L if structural dust cover
was removed, install onto the transmission and
engine (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - INSTALLATION).
8. Install structural dust cover (1) 7/16 bolts (2) and
tighten to 68 Nꞏm (50 ft. lbs.).
9. Install exhaust Y-pipe 5.7L engine.
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10. Install crossmember and tighten nuts (2) to 102
Nꞏm (75 ft. lbs.).
11. Install transmission mount bolts (1) and tighten to
68 Nꞏm (50 ft. lbs.).
12. Install starter motor (1) 5.7L.
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13. Connect transmission harnesses to clips on case
and connect switches.
14. Install slave cylinder and tighten cylinder nuts to
23 Nꞏm (200 in. lbs.).
15. Install transfer case and transfer case linkage 4x4
equipped.
16. Remove transmission jack.
17. Install propeller shaft/shafts with reference marks
aligned.
18. Install exhaust on the exhaust manifolds.
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19. Remove fill plug (1) on transmission (2) and fill to
bottom edge of fill plug hole.
20. Install fill plug and tighten to 57 Nꞏm (42 ft. lbs.).
21. Connect battery negative cable.
22. Install shift lever extension on shift tower and
lever assembly.
23. Slide boot down on shift lever extension and
install shift boot bezel and screws.
24. Install skid plate, if equipped.
ADJUSTMENTS
MAINSHAFT/COUNTERSHAFT BEARING PRELOAD
CAUTION: This procedure must be performed any time a mainshaft, countershaft or input shaft bearing or
shaft is replaced. Failure to follow these instructions will result in damaging the transmission.
MAINSHAFT
1. Set mainshaft, input shaft and countershaft into the
rear housing. Rotate the shafts to seat bearing in
rear housing.
2. Remove mainshaft bearing cup, shims and oiler
washer from the front housing.
3. Position Measurement Fixture 9592 (1) on front
housing over the mainshaft bearing cup bore.
4. Loosen the knob (2) on the fixture and lower the
shaft onto the mainshaft bearing cup (3) bore
shoulder. Then tighten the knob to hold the shaft.
5. Remove the fixture from the front housing.
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6. Place mainshaft shaft bearing cup on mainshaft
bearing.
7. Position Fixture 9592 (1) on rear housing over the
mainshaft bearing (2).
8. Loosen the knob (3) on the fixture (1). This will
allow the rod plunger to drop down on the bearing
cup.
9. Measure the gap (1) between the fixture shaft (2)
and the fixture plunger (3). Repeat measurement
on the opposite side of the mainshaft cup and
bearing. The average of the two measurement, will
be the size of the mainshaft select shim.
10. Install new oil supply washer and select shim in
front housing mainshaft bearing cup bore and
install bearing cup.