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Section 1586 (G56 Manual Transmission - (Service Information) - 2500 Hd): Assembly: 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.
GC0108983Courtesy of CHRYSLER GROUP, LLC
  1. Position mainshaft in Fixture (special tool #9605, Fixture) mounted in vise.
  2. Install second gear bearing (1) on mainshaft (2).
    GC0108982Courtesy of CHRYSLER GROUP, LLC
  3. Install second gear (1) on mainshaft (2).
    GC0109005Courtesy of CHRYSLER GROUP, LLC
  4. Install second gear stop ring (1) with teeth pointing up on second gear (2).
    GC0109006Courtesy of CHRYSLER GROUP, LLC
  5. Install second gear inner friction ring (1) on stop ring (2).
    GC0109007Courtesy of CHRYSLER GROUP, LLC
  6. Install second gear outer friction ring (1) on stop ring (2).
    GC0109008Courtesy of CHRYSLER GROUP, LLC
  7. Install second gear blocker ring (1) on stop ring (2).
    GC0109009Courtesy of CHRYSLER GROUP, LLC
  8. Install 1-2 synchronizer hub (1) on mainshaft and synchronizer rings (2).
    GC0108981Courtesy of CHRYSLER GROUP, LLC
  9. Install 1-2 synchronizer hub (1) and hub snap ring (2).
    GC0109010Courtesy of CHRYSLER GROUP, LLC
  10. Install 1-2 synchronizer sleeve (3) on the hub (2) and push sleeve to the bottom of the hub.
    NOTE:

    1-2 synchronizer sleeve (3) and hub (2) have one small tooth. They must be aligned to install synchronizer sleeve (3) on hub (2).

  11. Install 1-2 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind synchronizer sleeve (3).
    GC0109011Courtesy of CHRYSLER GROUP, LLC
  12. Install first gear blocker ring (1) on synchronizer hub (2).
    GC0109012Courtesy of CHRYSLER GROUP, LLC
  13. Install first gear outer friction ring (1) on synchronizer hub (2).
    GC0109013Courtesy of CHRYSLER GROUP, LLC
  14. Install first gear inner friction ring (1) on synchronizer hub (2).
    GC0109014Courtesy of CHRYSLER GROUP, LLC
  15. Install first gear stop ring (1) with teeth pointing down on synchronizer rings and hub (2).
  16. Hold first gear stop ring (1) on synchronizer rings (2) and center 1-2 synchronizer sleeve on the hub.
    GC0108978Courtesy of CHRYSLER GROUP, LLC
  17. Install first gear (1) and bearing (2).
    GC0083633Courtesy of CHRYSLER GROUP, LLC
  18. Heat thrust washer (1) and reverse gear bearing race (2) on bearing heater to a maximum of 150 Celsius (300° Fahrenheit).
    GC0108977Courtesy of CHRYSLER GROUP, LLC
  19. Using welding gloves or tongs, install thrust washer (2) and reverse gear bearing race (1) on mainshaft.
    GC0108976Courtesy of CHRYSLER GROUP, LLC
  20. Install reverse gear (1) and bearing (2).
    GC0109015Courtesy of CHRYSLER GROUP, LLC
  21. Install reverse gear inner friction ring (1) on reverse gear (2).
    GC0109016Courtesy of CHRYSLER GROUP, LLC
  22. Install reverse gear outer friction ring (1) on inner blocker ring (2).
    GC0109017Courtesy of CHRYSLER GROUP, LLC
  23. Install reverse gear blocker ring (1) on friction ring (2).
    GC0109018Courtesy of CHRYSLER GROUP, LLC
  24. Install reverse gear synchronizer hub (1) with snap ring (2) on the top on mainshaft.
    GC0083331Courtesy of CHRYSLER GROUP, LLC
  25. Heat mainshaft bearing (1) on bearing heater (2) to a maximum of 150 Celsius (300° Fahrenheit).
    GC0109019Courtesy of CHRYSLER GROUP, LLC
  26. Using welding gloves or tongs, install mainshaft (1) bearing (2) on mainshaft.
  27. On 4x4 transmission install mainshaft (1) bearing (2) snap ring.
    GC0108973Courtesy of CHRYSLER GROUP, LLC
  28. Install reverse synchronizer hub (1) detents (2).
    GC0108972Courtesy of CHRYSLER GROUP, LLC
  29. Install reverse gear (2) synchronizer sleeve (1) on hub and center sleeve on hub.
    GC0109020Courtesy of CHRYSLER GROUP, LLC
  30. Turn mainshaft and Fixture (special tool #9605, Fixture) over and secure in vise.
  31. Install third gear bearing (1) on mainshaft (2).
    GC0109021Courtesy of CHRYSLER GROUP, LLC
  32. Install third gear (1) on mainshaft (2).
    GC0109022Courtesy of CHRYSLER GROUP, LLC
  33. Install third gear stop ring (1) with teeth pointing up on third gear (2).
    GC0109023Courtesy of CHRYSLER GROUP, LLC
  34. Install third gear inner friction ring (1) on stop ring (2).
    GC0109024Courtesy of CHRYSLER GROUP, LLC
  35. Install third gear outer friction ring (1) on stop ring (2).
    GC0109025Courtesy of CHRYSLER GROUP, LLC
  36. Install third gear blocker ring (1) on stop ring (2).
    GC0108970Courtesy of CHRYSLER GROUP, LLC
  37. Install 3-4 synchronizer hub (1) on third gear synchronizer rings (2).
    GC0108969Courtesy of CHRYSLER GROUP, LLC
  38. Install third gear synchronizer hub (1) snap ring (2).
    GC0109010Courtesy of CHRYSLER GROUP, LLC
  39. Install 3-4 synchronizer sleeve (3) on hub (2) and push sleeve to the bottom of the hub.
    NOTE:

    3-4 synchronizer sleeve (3) and hub (2) have one small tooth. They must be aligned to install synchronizer sleeve (3).

  40. Install 3-4 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents (1) behind synchronizer sleeve (3).
    GC0109026Courtesy of CHRYSLER GROUP, LLC
  41. Install fourth gear blocker ring (1) on synchronizer hub (2).
    GC0109027Courtesy of CHRYSLER GROUP, LLC
  42. Install fourth gear outer friction ring (1) on synchronizer hub (2).
    GC0109028Courtesy of CHRYSLER GROUP, LLC
  43. Install fourth gear inner friction ring (1) on synchronizer hub (2).
    GC0109029Courtesy of CHRYSLER GROUP, LLC
  44. Install fourth gear stop ring (1) with teeth pointing down on synchronizer hub (2).
  45. Hold fourth gear stop ring (1) on synchronizer hub (2) and center 3-4 synchronizer sleeve on hub.
    GC0108966Courtesy of CHRYSLER GROUP, LLC
  46. Install fourth gear (1) and bearing (2).
    GC0109030Courtesy of CHRYSLER GROUP, LLC
  47. Heat fourth gear thrust washer (1) on bearing heater (2) to a maximum of 150 Celsius (300° Fahrenheit).
    GC0109031Courtesy of CHRYSLER GROUP, LLC
  48. Using welding gloves or tongs, install fourth gear (1) thrust washer (2).
    GC0108963Courtesy of CHRYSLER GROUP, LLC
  49. Install fourth gear (1) snap ring (2).
    GC0108962Courtesy of CHRYSLER GROUP, LLC
  50. Install sixth gear (1) and bearing (2) on mainshaft (3).
    GC0109032Courtesy of CHRYSLER GROUP, LLC
  51. Install sixth gear stop ring (1) on sixth gear (2).
    GC0109033Courtesy of CHRYSLER GROUP, LLC
  52. Install sixth gear friction ring (1) on stop ring (2).
    GC0109034Courtesy of CHRYSLER GROUP, LLC
  53. Install 5-6 synchronizer hub (1) on sixth gear synchronizer rings (2).
    GC0083331Courtesy of CHRYSLER GROUP, LLC
  54. Heat mainshaft bearing (1) on bearing heater to a maximum of 150 Celsius (300° Fahrenheit).
    GC0108960Courtesy of CHRYSLER GROUP, LLC
  55. Using welding gloves or tongs, install mainshaft bearing (1) on mainshaft.
  56. Install mainshaft bearing (1) snap ring (2).
    GC0108959Courtesy of CHRYSLER GROUP, LLC
  57. Install 5-6 synchronizer sleeve (1) on hub (2) and push sleeve to the bottom of the hub.
    GC0109010Courtesy of CHRYSLER GROUP, LLC
  58. Install 5-6 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind synchronizer sleeve (3).
    GC0109035Courtesy of CHRYSLER GROUP, LLC
  59. Install fifth gear friction ring (1) onto hub (2).
    GC0109036Courtesy of CHRYSLER GROUP, LLC
  60. Install fifth gear blocker ring with teeth pointing down (1) onto hub (2).
  61. Hold fifth gear blocker ring (1) onto hub (2) and center 5-6 synchronizer sleeve on hub (2).
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