Dodge D150 1990 Service Manual page 886

MANUAL TRANSMISSION 21 - 35
(2) I n s t a l l mainshaft a n d gear set assembly i n sup-
port plate (Fig. 33).
(3) Seat mainshaft center bearing snap r i n g (Fig.
33).
CAUTION: T h e center bearing snap ring is cham-
fered. Be sure the chamfered side of the snap ring
is facing the first speed gear.
(4) V e r i f y gear set i n s t a l l a t i o n position (Fig. 32).
INSTALLING GEAR SET IN GEAR CASE
(1) I n s t a l l a l i g n m e n t studs i n case (Fig. 31).
(2) I n s t a l l gear set a n d extension i n gear case
(Figs. 29, 30).
(3) I n s t a l l center support plate bolts ( F i g . 28).
T i g h t e n bolts t o 54 N*m (40 ft-lbs) torque.
(4) I n s t a l l square anti-spin p i n and reverse gear
t h r u s t washer (Fig. '27).
SHIFT RAIL AND FORK INSTALLATION
(1) I n s t a l l reverse gear and needle bearings (Fig.
26).
(2) I n s t a l l shift forks (Fig. 24).
(3) I n s t a l l 3-4 shift r a i l and i n t e r l o c k plate (Fig.
23).
(4) Position synchronizer i n reverse/OD shift fork.
T h e n i n s t a l l assembled components (Fig. 22).
(5) I n s t a l l reverse/OD synchronizer snap r i n g (Fig.
21).
OVERDRIVE GEAR INSTALLATION
(1) I n s t a l l mainshaft overdrive gear (Fig. 20).
(2) I n s t a l l overdrive gear t h r u s t washer a n d a n t i -
spin p i n (Fig. 19).
(3) I n s t a l l overdrive gear snap r i n g (Fig. 18).
(4) I n s t a l l overdrive countershaft gear w i t h tools C-
4982, C-4982-2, C-4982-6 and a wood block (Fig. 75).
Refer t o F i g u r e 17 for installer tool components.
Fig. 75 Installing Countershaft Overdrive Gear
(5) I n s t a l l countershaft overdrive gear snap r i n g
(Fig. 14).
FINAL ASSEMBLY
(1) I n s t a l l 1-2 shift r a i l and i n t e r l o c k plates (Fig.
13).
(2) I n s t a l l shift fork pins (Fig. 12).
(3) Seat overdrive shift r a i l a n d blocker s p r i n g
(Fig. 11).
(4) A p p l y bead o f sealer t o extension housing and
i n s t a l l housing over gears a n d o n center support
plate (Fig. 10). T i g h t e n a t t a c h i n g bolts to 54 N-m (40
ft-lbs) torque.
(5) I n s t a l l detent springs a n d bullets (Fig. 7).
(6) A p p l y bead o f sealer t o access cover and i n s t a l l
cover on case (Fig. 4). T i g h t e n cover bolts t o 28 N»m
(21 ft-lbs) torque.
(7) I n s t a l l shifter assembly. T i g h t e n shifter bolts to
28 N*m (21 ft-lbs) torque.
(8) I n s t a l l backup lamp switch.
(9) I n s t a l l d r a i n plug.
(10) I n s t a l l countershaft gear O - r i n g and expansion
p l u g .
TRANSMISSION INSTALLATION
(1) L i g h t l y lubricate i n p u t shaft a n d f r o n t bearing
r e t a i n e r w i t h Mopar h i g h temperature grease.
(2) A l i g n i n p u t shaft w i t h clutch disc a n d slide
transmission i n t o place on housing.
(3) I n s t a l l and t i g h t e n transmission-to-clutch hous-
i n g bolts.
(4) I n s t a l l crossmember a n d insulator.
(5) I n s t a l l transfer case, i f equipped.
(6) Remove supports.
(7) I n s t a l l speedometer adapter a n d distance sen-
sor.
(8) Connect backup lamp switch wires.
(9) A l i g n and connect propeller shaft(s).
(10) Refill transmission w i t h 10W-30, A P I SG/CD
engine o i l .
(11) Lower vehicle and i n s t a l l upper p a r t o f shift
lever.