Page 2633 of 5267
9. Install shaft bolt and align idler gear shaft (1) with
shaftbolt(2).
10. Apply Mopar
Lock & Seal Adhesive or equivalent
to idler shaft bolt. Tighten bolt (1) in housing (2) to
25 Nꞏm (18 ft. lbs.).
Page 2634 of 5267
FRONT HOUSING
1. Install mainshaft and countershaft bearings in front
housing with hammer and driver.
2. Install mainshaft bearing retainer (1) and counter-
shaft bearing retainers (2). Apply Mopar
Lock &
Seal Adhesive or equivalent to retainer bolts and
tightento10Nꞏm(88in.lbs.).
3. Install mainshaft (1) and countershaft (2) in build
Fixture 9626 (3).
Page 2638 of 5267
10. Apply MoparLock & Seal Adhesive or equivalent
to shift fork pivot bolts. Install 5-6 (1) and 3-4 (2)
shift fork pivot bolts, in both sides of the front
housing and tighten to 35 Nꞏm (26 ft. lbs.).
NOTE: Verify shift fork pivot holes are aligned with
pivot bolt holes before installing bolts.
11. Install two detents (1) in the side of the front hous-
ing (2).
Page 2640 of 5267
3. Install intermediate plate (1) bolts (2) and tighten to
22 Nꞏm (16 ft. lbs.).
4. Install interlock plate washers (1) on support (2).
5. Install interlock plate (2) and tighten bolts (1) to 10
Nꞏm (88 in. lbs.).
Page 2642 of 5267
9. Install second gear outer friction ring (1) on second
gear (2).
10. Install second gear blocker ring (1) on second
gear (2).
Page 2643 of 5267
11. Align 1-2 synchronizer hub (1) with blocker ring on
mainshaft and install hub with Installer D-389 (2).
NOTE: If 1-2 synchronizer hub is installed incor-
rectly the snap ring groove will not be visible.
12. Install 1-2 synchronizer hub (1) snap ring (2).
Page 2644 of 5267
13. Install 1-2 synchronizer hub (1) detents (2).
14. Install 1-2 synchronizer sleeve (2) on 1-2 hub (1).
NOTE: Align grooves in the sleeve with detents in
hub.
15. Install first gear blocker ring (1) on 1-2 hub (2).
Page 2647 of 5267
22. Install reverse gear bearing (1) on bearing race
(2).
23. Install reverse gear (1) on mainshaft (2).
24. Install reverse gear friction/blocker ring (1) on
reverse gear (2).