Rear Housing

WARNING: This page is about a different car, the 2015 RAM 3500 HD and 2015 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Installing Countershaft Cup

Courtesy of CHRYSLER GROUP, LLC

Install countershaft bearing cup with Installer (special tool #9589, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).

Fig 2: Installing Mainshaft Cup
Courtesy of CHRYSLER GROUP, LLC
Install mainshaft bearing cup with Installer (special tool #9588, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).
Install output shaft seal with Installer (special tool #9598, Installer, Seal).

Fig 3: Idler Gear & Bearing
Courtesy of CHRYSLER GROUP, LLC
Install reverse idler bearing (1) into idler gear (2).

Fig 4: Reverse Idle Gear
Courtesy of CHRYSLER GROUP, LLC
Install idler gear (1) with taller thrust face up into rear housing (2) and off to the side. For mainshaft/countershaft installation clearance.

Fig 5: Identifying Strap And Shift Rails
Courtesy of CHRYSLER GROUP, LLC
Tie strap (2) shift rails (1) together.

Fig 6: Identifying Shift Forks
Courtesy of CHRYSLER GROUP, LLC
Install reverse (1), 1-2 (2) and 3-4 (3) shift rails and forks as and assembly on synchronizer sleeves.

Fig 7: Mainshaft And Shift Rails
Courtesy of CHRYSLER GROUP, LLC
Install mainshaft with shift rails (2) into the rear housing. Tilt the mainshaft then tilt the countershaft (1) into the housing.

Fig 8: Identifying Oil Slinger And Mainshaft Gears
Courtesy of CHRYSLER GROUP, LLC
Position first/reverse oil slinger (1) between the mainshaft first (2) and reverse gears, then straighten the shafts in the housing.
CAUTION:
Oil slinger is fragile and can crack during installation. Failure to follow these instructions will result in cracking the oil slinger and lack of oil to first/reverse bearing.

NOTE:
The transmission may or not be equipped with the oil slinger. Service replacement parts will come with an oil slinger. It is not necessary to remove the oil slinger if the original part was not equipped with an oil slinger.

Fig 9: Reverse Idler Shaft
Courtesy of CHRYSLER GROUP, LLC
Position reverse idler gear and install idler shaft (2) with bolt (1).

Fig 10: Reverse Idler Shaft Pin
Courtesy of CHRYSLER GROUP, LLC
Install reverse idler gear shaft bolt (1) into rear housing (2) and tighten to 58 N.m (43 ft. lbs.).

Fig 11: 5-6 Shift Fork Shoe
Courtesy of CHRYSLER GROUP, LLC
Install 5-6 shift shoe narrow ends (1) into the 5-6 synchronizer sleeves (2).

Fig 12: 5-6 Shift Fork
Courtesy of CHRYSLER GROUP, LLC
Install 5-6 shift fork (1) into the shift rail.