DMT6 Manual Transmission - Assembly

ASSEMBLY





1. Using Puller 9664 (2) and a Slide Hammer (1) remove the case side differential bearing cup (3) from the case (4).





2. Using Bearing Cup Installer D-129 (2) and Handle C-4171 (1) install the differential bearing cup (3) into the case (4).





3. Using Puller 9664 (2) and a Slide Hammer (1) remove the bellhousing side differential bearing cup (3) from the case (4).






NOTE: The differential pre-load will be determined later in this procedure. Save measure and mark this shim for differential installation.

4. Remove the differential pre-load shim (2) located under the differential bearing cup (1) clean case and reinstall the shim. The original pre-load shim will be used for a starting point.





5. Using Bearing Cup Installer D-129 (2) and Handle C-4171 (1) install the differential bearing cup (3) into the case on the bellhousing side (4).





6. Using Puller 9664 (2) and a Slide Hammer C-637 (1) remove the case side 5th/6th/reverse gear output shaft bearing cup (3) from the case (4).





7. Using Bearing Cup Installer C-4628 (2) and Handle C-4171 (1), install the case side 5th/6th/reverse gear output shaft bearing cup (3) into the case (4).





8. Using Puller 9664 (1) and a Slide Hammer C-637 remove the case side 1st-4th gear output shaft bearing cup (2) from the case (3).





9. Using Bearing Cup Installer C-4628 (2) and Handle C-4171 (1) install the case side 1st-4th gear output shaft bearing cup (3) into the case (4).





10. Remove the input shaft seal (2) using Installer MD-998323 (1).





11. Using Bearing Remover C-4660-A (1), remove the input shaft bearing (2) from the bellhousing side case (3).





12. Using Installer 9045 (2) and Handle C-4171 (1), install the input shaft bearing (3) into the bellhousing side case (4).






NOTE: Insure that the new stakes are at the same depth as the old stakes.

13. Using a Punch (1) stake the housing at the case (2) in three spots between the original stakes (3).






NOTE: Seal should be set to 4mm (.16 in).

14. Install the input shaft seal (2) to 4mm (.16 in) sub-flush, using Installer MD-998323 (1).






NOTE: If the original shim is missing or broke always start out with the middle shim size in the new parts package.

15. Install the 5th/6th/reverse oil tube (3) and the shim (2) into the bellhousing side of the case (4), place the 5th/6th/reverse output shaft bearing cup (1) in place.





16. Using Bearing Cup Installer 10036 (2) and Handle C-4171 (1) install the 5th/6th/reverse output shaft bearing cup (3) into the bellhousing side of the case.






NOTE: If the original shim is missing or broken always start out with the middle shim size in the new parts package.

17. Install the 1st/4th output oil tube, shim and output shaft bearing cup into place.





18. Using Bearing Cup Installer 10036 (2) and Handle C-4171 (1) install the 1st/4th output shaft bearing cup (3) into the bellhousing side of the case.

NOTE: At this point the shim thickness for the differential and both output shafts will need to be determined by doing a turning torque procedure.

19. Install the differential and the output shafts one at a time to perform the adjustment procedure Adjustments.





20. Place both output shafts (1, 3) and the input shaft (2) onto the Fixture 10037 (4).





21. Install the shift forks (5) and shift rails (4) onto the output shafts (1, 3).





22. Install Tie Straps around all three shafts and forks.





23. Install the assembly that is strapped together into the case (1, 2, 3, 4, 5, 6, 7, 8, 9).
24. Cut the tie straps.
25. Install the differential (10).
26. Install the magnet into the case (11).





27. Once proper turning torque has been established, Draw a bead of MOPAR(R) Gasket Maker, Loctite(R) 518, or equivalent, on the flat clean surface of the case mating flange. Install clutch bellhousing case onto the case side.
28. Install and tighten case bolts to 32 Nm (24 ft. lbs.).





29. Install the bellhousing side case retaining bolts (8) and tighten to 32 Nm (24 ft. lbs.).
30. Draw a bead of MOPAR(R) Gasket Maker, Loctite(R) 518, or equivalent, on the flat clean surface of the case mating flange. install the selector mechanism (4).

NOTE: insure forks and selector mechanism are in neutral.

31. Install the selector mechanism bolts (1) and tighten to 26 Nm (19 ft. lbs.).





32. Install the newinput shaft bearing retainer bolts (2) and tighten to 30 Nm (22 ft. lbs.).
33. Install the differential seals. . Axle Drive Shaft Seal - Installation





34. Install the clutch slave cylinder (4).
35. Install the clutch slave cylinder bolts (3) and tighten to 10 Nm (89 in. lbs.).
36. Install the breather (1) and clip (2).





37. Install the shift cable bracket and bolts, tighten the bolts to 30 Nm (22 ft. lbs.).