Part 1

ASSEMBLY





NOTE: Always use ATF on all moving parts during this assembly procedure.

1. Use Bearing Cup Remover 9664 (2) and appropriate Slide Hammer (1) to remove the output shaft #2 tapered bearing cup (3) from the transmission rear case.




2. Remove the output shaft #2 bearing cup shim (1) from the transmission rear case (2).

NOTE: A turning torque will determine the correct shim to be installed. This can be found at the end of the assembly procedure.

3. Install the correct output shaft #2 bearing cup shim into the transmission case.




4. Install the output shaft #2 bearing cup (3) into the transmission rear case using Handle C-4171 and Seal/Cup Installer L-4520.




5. Remove the output shaft #2 bearing cup (3) using Bearing Cup Remover 9664 (2) and appropriate slide hammer (1).




6. Remove the oil slinger (1) under the output shaft #2 cup on the bellhousing side.
7. Install the oil slinger (1) in the case (2) for the compounder shaft bearing cup on the bellhousing side, insure the tab (3) is lined up with cutout in case (2).




8. Use Handle C-4171 and Bearing Cup Installer D-144, inverted to install the compounder shaft cup on the bellhousing side case.




9. Remove the input shaft case bearing (3) (bellhousing side) using Bearing Cup Remover 7794-A (1) and appropriate slide hammer.




10. Using a screwdriver (1) remove the input shaft seal (2).




11. Using handle C-4171 and Installer 9935 (2) install the new input shaft oil seal.




12. Install the input shaft case bearing (2) using Handle C-4171 (1) and Bearing Installer C-4657 (2).




13. Using Bearing Cup Remover 7794-A (2) and appropriate slide hammer (1) remove the output shaft #1 bearing (3) from the case (1).




14. Remove the output shaft oil slinger (2) from case.
15. Install the output shaft oil slinger (2) into the case, insure the tab (3) is lined up with cutout in case (2).




16. Using Handle C-4171 (1) and Bearing Installer C- 4308 inverted (2) install output bearing (3) to case (4).




17. Remove the case side differential bearing cup using Handle C-4171 (1) and Bearing Cup Installer 9589 (2), inverted.




18. Remove the case side differential bearing cup shim (1).

NOTE: The case side differential bearing cup shim (1) will be left out to find end play then installed to check turning torque later in the assembly procedure. DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

19. Install the correct case side differential bearing cup shim (1).




20. Install the case side differential bearing cup (3) using Handle C-4171 (1) and Bearing Cup Installer D-111 (2).




21. Install the bellhousing side differential bearing cup (3) using Handle C-4171 (1) and Bearing Cup Installer D-111 (2) on FWD transmissions and Bearing Cup Installer 8151 (2) on AWD transmissions.




22. Install oil baffle (2) and bolts (1), tighten bolts to 9 Nm (80 in. lbs.).




23. Install the oil feed trough (1) into the case (2).




24. Install the magnet (1) into the case.




25. Install the differential (1) into the case (5).
26. Verify differential bearing preload and turning torque. Refer to DIFFERENTIAL BEARING PRELOAD ADJUSTMENT procedure STEP 10.




27. Install the output #1 (1) and input shaft (2) into case together.




28. Install the output shaft (2) hold down bolt (4) and tighten to 11 Nm (97 in. lbs.).




29. Install the reverse idler gear assembly (1) into the case (2).




30. Install the output shaft #2 (4) into case.




31. Install the oil slinger (1) and bolts (2) tighten the bolts to 9 Nm (80 in. lbs.).





NOTE: Clock the reverse idler (1) with hole as shown for installation of anti-rotation bolt.

32. Install the reverse idler gear (1) hold down bolt (2) and tighten to 11 Nm (97 in. lbs.).




33. Install the first and second gear shift fork (1) onto the first and second gear synchronizer (2).




34. Install the third and fourth gear shift fork (1) onto the third and fourth gear synchronizer.




35. Install the shift rail arm (1) onto the stand (2).




36. Install the pivot shaft (1) into the case.




37. Install the shift rail bracket pivot pin (1) and the new pivot pin E-clip (2).




38. Install the third and fourth gear shift bracket (1).




39. Install the third and fourth gear shift rail (1) into the case and shift fork (4).




40. Install the new roll pin at the third and fourth gear shift rail.




41. Install the first and second gear shift rail (1).




42. Install the new roll pin at the third and fourth gear shift fork to rail (1).




43. Install the new bolt (2) holding the first and second gear shift fork (3) to the rail and tighten to 20 Nm (177 in. lbs.).




44. Install the fifth and sixth gear shift fork (2).




45. Install the reverse gear shift fork (1).




46. Install the fifth and sixth gear shift rail (1) into the case and shift fork (2).




47. Install the new bolt (2) holding the fifth and sixth gear shift fork (3) to the fifth and sixth gear shift rail (1) and tighten to 20 Nm (177 in. lbs.).




48. Install the reverse shift rail (1) into the case (3) and shift fork (2).




49. Install the new bolt (1) holding the reverse shift fork (5) to the reverse shift rail (6) and tighten to 20 Nm (177 in. lbs.).




50. Install third and fourth gear shift rail detent ball.
51. Install third and fourth gear shift rail detent spacer (3) and spring (2).




52. Install a new third and fourth gear shift rail detent plug (1) and tighten to 22 Nm (195 in. lbs.).




53. Install first and second gear shift rail detent ball.
54. Install first and second gear shift rail detent spacer and spring.
55. Install a new first and second gear shift rail detent plug (1) and tighten to 22 Nm (195 in. lbs.).




56. Install the reverse shift rail detent ball (2).




57. Install the reverse shift rail detent spacer (3) and spring (2).




58. Install a new reverse shift rail detent plug (1) and tighten to 22 Nm (195 in. lbs.).




59. Install fifth and sixth gear shift rail detent ball (2).




60. Install fifth and sixth gear shift rail detent spacer (3) and spring (2).




61. Install a new fifth and sixth gear shift rail detent plug (1) and tighten to 22 Nm (195 in. lbs.).




62. If this is the final assembly draw a bead (1) of MOPAR(R) Gasket Maker, Loctite(R) 518, or equivalent, on the flat surface of the case mating flange (2).