- If previously removed, install input shaft bearing in front housing bore (see Fig 1). Install snap ring and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.
- Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (see Fig 1). Large diameter side of bearing cage goes toward countershaft (see Fig 2). Small diameter side goes toward bearing race in housing.
- Reach into countershaft front bearing with finger, and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place. This avoids having rollers becoming displaced during housing installation.
- Apply small amount of petroleum jelly to shift shaft bushing in front housing.
- Apply 1/8 in. wide bead of Mopar Gasket Maker or equivalent, to mating surfaces of front and rear housings (see Fig 3).
- Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain.
- Work front housing downward onto geartrain until seated on rear housing.
CAUTION:
If the front housing will not seat on the rear housing, either the shift components are not in Neutral, or one or more components are misaligned. Do not force the front housing into place. This will only result in damaged components.
- Tap rear housing alignment dowels back into place with hammer and pin punch. Both dowels should be flush fit in each housing. Have helper hold transmission upright while dowels are tapped back into place.
- Place transmission in horizontal position.
- Apply Mopar Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (see Fig 4).
- Install and start housing attaching bolts by hand (see Fig 4). Then tighten bolts to 34 N.m (25 ft. lbs.)
- Install shift shaft bushing lock bolt (see Fig 5). Apply Mopar Gasket Maker or equivalent, to bolt threads, shank and underside of bolt head before installation.
CAUTION:
If the lock bolt cannot be fully installed, do not try to force it into place. Either the shift shaft is not in Neutral or the shaft bushing (or lever) is misaligned.
- Lubricate then install shift shaft detent plunger in housing bore (see Fig 6). Lubricate plunger with petroleum jelly or gear lubricant. Verify plunger is fully seated in detent notch in shift shaft.
- Install detent spring inside plunger (see Fig 6).
- Install plug on detent spring and compress spring. Then drive detent plug into transmission case until plug seats.
- Install backup light switch (see Fig 7).
- Install input shaft snap ring (see Fig 8).
- Install new oil seal in front bearing retainer with Installer 6448 (see Fig 9).
- Apply bead of Mopar silicone sealer or equivalent to flange surface of front bearing retainer (see Fig 10).
- Align and install front bearing retainer over input shaft and onto housing mounting surface (see Fig 11). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.
NOTE:
Ensure no sealer gets into the oil feed hole in the transmission case or bearing retainer.
- Install and tighten bearing retainer bolts to 7-10 N.m (5-7 ft. lbs.) (see Fig 12).