Page 2705 of 5267
22. Install 5-6 gear (2) on mainshaft with Installer
9391(1).
23. Install fifth gear stop ring.
24. Install fifth gear bearing and gear (1) on counter-
shaft (2).
Page 2706 of 5267
25. Install fifth gear (1) thrust washer (2).
26. Installnewfifth gear (1) snap ring (2).
27. Install reverse shift fork (1) and synchronizer (2)
sleeve onto main shaft.
Page 2707 of 5267
28. Install reverse gear (3) on countershaft with
Installer 9391 (2) bolt, bearing and washer and 1
3/16 half inch drive socket (1).
29. Install reverse gear snap ring on countershaft.
30. Install reverse synchronizer (1) snap ring (2).
31. Installnewreverse shift fork (1) snap ring (2) with
the flat side facing rearward.
Page 2708 of 5267
32. Install reverse gear (3), bearing (5), wave washer
(2) and brass blocker ring (1) on mainshaft (4).
33. Install reverse gear (1) thrust washer (2) and snap
ring (4).
.
34. Install mainshaft (3) roller bearing (4), spacers (2)
and snap ring.
35. Apply Mopar
Gasket Maker to tail housing seal-
ing surface.
Page 2709 of 5267
36. Install the six tail housing (1) to case bolts (2) and
tighten bolts to 41 Nꞏm (30 ft. lbs.).
37. Install two tail housing nuts (2) on top of transmis-
sion tail housing (3).
38. Slide offset lever (1) onto shaft in tail housing (2).
.
Page 2710 of 5267
39. Install offset lever (3) roll pin with hammer (1) and
punch (2)..
40. Install Mopar
Gasket Maker to the shift cover
sealing surface and position cover on the trans-
mission.
41. Install shift cover four mounting bolts and tighten
to 18 Nꞏm (13 ft. lbs.).
INSTALLATION
1. Slide transmission back into the clutch and seat
against clutch housing.
2. Install transmission bolts to clutch housing bolts
and tighten to and tighten bolts to 35 Nꞏm (26 ft.
lbs.)
3. Install transmission crossmember (2) and bolts/nuts
(1).Tightennutsto61Nꞏm(45ft.lbs.).
4. Install transmission mount (2) bolts (1) and tighten
to 41 Nꞏm (30 ft. lbs.).
5. Remove transmission jack.
Page 2711 of 5267
6. Install back up lamp switch (2) connector (1).
7. Install fuel line to top plate stud.
8. Install reverse lockout solenoid (1) harness connec-
tor (2).
9. Install hydraulic clutch quick connector (1) to the
slave cylinder.
10. Clean transmission shifter tower sealing surfaces
and apply a bead of Mopar
Gasket Maker.
11. Install shifter tower and tighten bolts to 18 Nꞏm
(156 in. lbs.).
12. Install propeller shaft with reference marks
aligned.
CAUTION: The drive shaft strap bolts must be
replaced or cleaned and Loctite
242 applied.
CAUTION: Replace drive shaft joint straps when-
ever they are removed. The straps slightly deform
when torqued in place. Reuse of the straps may
result in reduced clamp load on the universal joint
cap.
Page 2712 of 5267
ADJUSTMENTS
ADUSTMENTS
MAINSHAFT BEARINGS PRELOAD
1. Install input shaft (2) in to front adapter.
2. Install mainshaft and bearing.
3. Install case and bolt together using all bolts.
4. Rotate input shaft and mainshaft to seat bearings.
5. Screw Stud 8161 into the case and set up dial indi-
cator (1) on the end of the mainshaft (2).
6. Zerothedialindicator,thenpushupontheinput
shaft and record the end play reading. If there is no
end play, a thinner shim must be installed behind
the input shaft bearing cup in the front adapter.
Install .010 in. thinner shims until an end play is
obtained.
7. Once an end play reading is obtained, add .002 in.
to the reading.
8. Install shim(s) behind the input shaft bearing cup in
the front adapter.