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Section 1586 (G56 Manual Transmission - (Service Information) - 2500 Hd): Disassembly: MAINSHAFT

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
GC0108956Courtesy of CHRYSLER GROUP, LLC
  1. Remove reverse (1) 1-2 (2) and 3-4 (3) shift forks and shift rails as an assembly from mainshaft.
    GC0108957Courtesy of CHRYSLER GROUP, LLC
  2. Position mainshaft in Fixture (special tool #9605, Fixture) mounted in a vise with sixth gear up.
  3. Remove fifth gear synchronizer rings (1) from 5-6 synchronizer hub (2).
    GC0108958Courtesy of CHRYSLER GROUP, LLC
  4. Slowly pull 5-6 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).
    GC0108959Courtesy of CHRYSLER GROUP, LLC
  5. Remove 5-6 synchronizer sleeve (1) from hub (2).
    GC0108960Courtesy of CHRYSLER GROUP, LLC
  6. Remove mainshaft bearing (1) snap ring (2).
    GC0108961Courtesy of CHRYSLER GROUP, LLC
  7. Remove mainshaft bearing (1), 5-6 synchronizer hub (2), and sixth gear synchronizer rings (3) with three jaw puller (4). Position puller jaws under sixth gear synchronizer rings (3).
    GC0108962Courtesy of CHRYSLER GROUP, LLC
  8. Remove sixth gear (1) and bearing (2) from mainshaft (3).
    GC0108963Courtesy of CHRYSLER GROUP, LLC
  9. Remove fourth gear (1) snap ring (2).
    GC0108964Courtesy of CHRYSLER GROUP, LLC
  10. Remove fourth gear thrust washer (1) with Puller (special tool #9594, Remover, Gear & Synchro). Position puller under fourth gear synchronizer stop ring (2).
    GC0108965Courtesy of CHRYSLER GROUP, LLC
  11. Install Bridge (special tool #938, Bridge) (1) into Puller (special tool #9594, Remover, Gear & Synchro) (2) and remove fourth gear thrust washer (3).
    GC0108966Courtesy of CHRYSLER GROUP, LLC
  12. Remove fourth gear (1) and bearing (2).
    GC0108967Courtesy of CHRYSLER GROUP, LLC
  13. Remove fourth gear synchronizer rings (1) from 3-4 synchronizer hub (2) and mark installation reference.
    GC0108968Courtesy of CHRYSLER GROUP, LLC
  14. Slowly pull 3-4 synchronizer sleeve (1) up on hub enough to remove detents and springs (2).
  15. Remove 3-4 synchronizer sleeve (1) from hub.
    GC0108969Courtesy of CHRYSLER GROUP, LLC
  16. Remove 3-4 synchronizer hub (1) snap ring (2).
    GC0108970Courtesy of CHRYSLER GROUP, LLC
  17. Remove 3-4 synchronizer hub (1) and third gear synchronizer rings (2). Mark components for installation reference.
    GC0108971Courtesy of CHRYSLER GROUP, LLC
  18. Remove third gear (1) and bearing (2).
    GC0108972Courtesy of CHRYSLER GROUP, LLC
  19. Turn mainshaft and Fixture (special tool #9605, Fixture) and secured in vise.
  20. Remove 4x4 mainshaft snap ring.
  21. Remove reverse gear synchronizer sleeve (1) from reverse gear (2) synchronizer hub.
    GC0108973Courtesy of CHRYSLER GROUP, LLC
  22. Remove reverse gear synchronizer hub (1) detents (2).
    GC0108974Courtesy of CHRYSLER GROUP, LLC
  23. Remove mainshaft bearing (1) with Bridge (special tool #938, Bridge) (2) and bearing Puller (special tool #9647, Puller) (3).
    GC0108975Courtesy of CHRYSLER GROUP, LLC
  24. Position puller (1) behind reverse synchronizer hub and outer blocker ring (2).
    GC0108976Courtesy of CHRYSLER GROUP, LLC
  25. Remove reverse gear (1) and bearing (2).
    GC0108977Courtesy of CHRYSLER GROUP, LLC
  26. Remove reverse gear bearing race (1) and thrust washer (2). Use Puller (special tool #9646, Puller, Gear) and Bridge (special tool #938, Bridge) on first gear (3) to pull off reverse gear bearing race (1) and thrust washer (2).
    GC0108978Courtesy of CHRYSLER GROUP, LLC
  27. Remove first gear (1) and bearing (2).
    GC0108979Courtesy of CHRYSLER GROUP, LLC
  28. Remove first gear synchronizer rings (1) from 1-2 synchronizer hub (2) and mark for installation reference.
    GC0108980Courtesy of CHRYSLER GROUP, LLC
  29. Slowly pull 1-2 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).
    GC0108981Courtesy of CHRYSLER GROUP, LLC
  30. Remove 1-2 synchronizer hub (1) snap ring (2) and remove hub with second gear synchronizer rings. Mark components for installation reference.
    GC0108982Courtesy of CHRYSLER GROUP, LLC
  31. Remove second gear (1) from mainshaft (2).
    GC0108983Courtesy of CHRYSLER GROUP, LLC
  32. Remove second gear bearing (1) from mainshaft (2).
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