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21 - 42
MANUAL TRANSMISSION
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(6) I n s t a l l d r i v e p i n i o n a n d b a l l bearing assembly
m a k i n g sure p i l o t rollers r e m a i n i n place.
(7) I n s t a l l rear bearing r e t a i n e r and gasket.
(8) I n s t a l l drive p i n i o n b e a r i n g retainer w i t h gas-
ket.
(9) Check synchronizer end play after a l l mainshaft
components are installed a n d tightened. Two sets o f
equal feeler gauges are needed t o check end play
(Fig. 3). E n d play should be 1.27 - 1.78 m m (.050 t o
.070 inch). Keep gauges as close t o both sides o f the
mainshaft as possible for best results. I f necessary,
disassemble mainshaft and change s h i m thickness.
(10) Shift gears and/or synchronizer i n t o a l l speed
positions and check for free r o t a t i o n .
(11) Lubricate transmission parts w i t h gear o i l be-
fore i n s t a l l i n g cover.
(12) Move transmission gears i n t o n e u t r a l position.
(13) Lower cover w i t h n e w gasket o n case, over
transmission.
(14) Carefully engage forks i n t o proper gears and
lower cover i n t o place.
(15) I n s t a l l one shouldered a l i g n m e n t screw and
split washer i n each second-from-front hole o n each
side o f cover and test gears for free r o t a t i o n by shift-
i n g gears t h r o u g h cover tower w i t h long screwdriver.
(16) I n s t a l l r e m a i n i n g cover screws.
TRANSMISSION INSTALLATION
(1) Lubricate t h e p i l o t b u s h i n g w i t h Mopar h i g h
temperature wheel b e a r i n g grease.
(2) M o u n t transmission o n suitable j a c k and slide
assembly under vehicle.
(3) Raise transmission u n t i l d r i v e p i n i o n i s cen-
tered i n clutch housing bore.
(4) R o l l transmission slowly f o r w a r d u n t i l p i n i o n
shaft enters c l u t c h disc. T u r n p i n i o n shaft
u n t i l
splines are aligned, t h e n w o r k transmission forward
u n t i l seated against c l u t c h housing. D o n o t allow
transmission t o h a n g after p i n i o n shaft has entered
the clutch disc.
(5) I n s t a l l transmission t o c l u t c h housing bolts and
t i g h t e n t o 142 Nnn (105
ft-lbs).
(6) I n s t a l l transmission rear m o u n t assembly o n
crossmember.
(7) I n s t a l l crossmember.
(8) Remove engine support fixture a n d disengage
hooks from t h e frame side r a i l s .
(9) I n s t a l l shift lever.
(10) I n s t a l l transfer case i f equipped.
(11) F i l l transmission w i t h required l u b r i c a n t .
(12) Road test vehicle t o make sure transmission
shifts smoothly a n d operates quietly.
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