Page 2649 of 5267
28. Install main shift rail (1) bearings (2) on main shift
rail.
29. Install main shift rail (1) through rail support (2)
and housing, then rotate counterclockwise into
place.
30. Install 1-2 shift fork then, install 1-2 shift rail (2)
into shift fork and housing. Install shift fork roll pin
(1).
Page 2650 of 5267
31. Install reverse shift rail (1) into the housing. Then
install reverse shift fork (2) and pull shift rail (1)
up into the shift fork.
32. Install reverse shift fork roll pin (1).
WARNING: Use tongs when handling heated com-
ponents. Failure to follow these instructions will
result in personal injury.
CAUTION: A bearing heater (2) is used to heat
Plug 9619-2 (1). Use only a bearing heater/hot
plate and follow manufacturer’s instructions. Heat
components to 100 - 177 Celsius (212° Min. - 350°
Max Fahrenheit). Never use an open flame to heat
components. Never leave components on heater
for an extended amount of time. If component is
discolored after heating, the component has been
overheated and must not be used. Failure to fol-
low these instructions will result in component
damage.
33. Heat Plug 9619-2 (1) with bearing heater (2) to a
maximum of 177 Celsius (350° Fahrenheit).
Page 2651 of 5267
34. With tongs place Plug 9619-2 in rear housing
mainshaft bearing (2). Allow plug to heat bearing
for two minutes.
35. Apply a bead of Mopar
Gasket Maker or equiv-
alent to the front housing sealing surface.
36. Remove plug and install rear housing (1) on front
housing (2).
37. Install housing bolts and tighten to 22 Nꞏm (16 ft.
lbs.).
38. Install output shaft seal in rear housing (1) with
Installer 9629 (2).
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39. Install 4x4 transmission output shaft nut with
Socket 9584 and tighten to 200 Nꞏm (147 ft. lbs.).
Then loosen nut and tighten to 170 Nꞏm (125 ft.
lbs.).
40. Drive output shaft flange onto the output shaft
with Installer D-389.
41. Install 4x2 transmission output shaft flange (1)
and tighten bolt (2) to 200 Nꞏm (147 ft. lbs.). Then
loosen bolt and tighten to 170 Nꞏm (125 ft. lbs.).
Remove Wrench 9586 from input shaft.
42. Install two detent plugs in the top of the rear
housing.
43. Install large detent plunger (1) and spring (2) in
the side of the rear housing.
Page 2653 of 5267
44. Install large detent plug (1) in the side of the rear
housing (2).
45. Install back up lamp switch (1) and tighten bolt (2)
to 10 Nꞏm (88 in. lbs.). Then lay transmission
down on bench.
46. Install input shaft (1) snap ring (2).
Page 2654 of 5267
47. Install input shaft seal in front housing with
Installer 9620 (1) and Tube C-3717 (2).
48. Install clutch bearing release support (1) and
tighten bolts (2) to 10 Nꞏm (88 in. lbs.).
49. Install Wrench 9586 (1) on input shaft (2).
Page 2655 of 5267
50. Install countershaft bolt (1) in front housing.
Tighten bolt (1) to 90 Nꞏm (66 ft. lbs.).
51. Install countershaft plug in front housing (1) with
Installer 9622 (2) and Handle C-4171.
52. Install the cover plate for the second shift tower
location, if necessary.
53. Apply Mopar
Lock & Seal or equivalent to shifter
socket threads and install shifter socket (1).
Page 2656 of 5267
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.
3. Support and secure transmission to jack.
4. Raise and align transmission input shaft with clutch
disc, then slide transmission into place.
5. Verify front housing is fully seated. Install transmis-
sion bolts without washers (1) and tighten bolts into
the engine to 41 Nꞏm (30 ft. lbs.). Tighten the bolts
with washers (2) into the transmission to 68 Nꞏm
(50 ft. lbs.).
6. Install rear crossmember (1) and tighten nuts to
102 Nꞏm (75 ft. lbs.).
7. Install transmission rear mount (2) bolts and tighten
to 68 Nꞏm (50 ft. lbs.).