Chrysler DODGE D150 1993 Service Manual page 1041

21 - 40 NV4500 TRANSMISSION OVERHAUL
SPECIAL
TOOL
6443
FIFTH
GEAR
NUT
SPECIAL
TOOL
6441
OR
6442
RATCHET
WRENCH
BREAKER
BAR
J9221-92
Fig. 149 Fifth Gear Nut installation
(6) Lock mainshaft gears by shifting all synchro
sleeves into engaged position,
(7) Position Spline Socket Wrench 6441 or 6442 on
mainshaft splines. Then install breaker bar in socket
wrench and wedge b a r against workbench.
(8) Tighten fifth gear n u t with N u t Wrench 6443
and high capacity torque wrench. Required torque on
n u t is 339-475 N*m (250-350 ft. lbs.). Have helper
hold transmission steady if necessary. N u t can also
be tightened by striking Wrench 6443 with heavy-
copper mallet then checking with torque wrench.
COUNTERSHAFT
FIFTH GEAR AND SYNCHRO
INSTALLATION
(1) Install t h r u s t washer pin in countershaft (Fig.
150).
0 /
COUNTERSHAFT
J9221-234
Fig. 150 Installing Fifth Gear Thrust Washer Pin
(2) Install t h r u s t washer on countershaft. Turn
washer until pin engages in washer notch (Fig. 151).
Flat side of washer faces rear and cone side to front
as shown.
J9221-235
Fig. 151 installing Fifth Gear Thrust Washer
(3) Lubricate and install fifth gear bearings on
countershaft (Fig. 152).
(4) Install bearing spacer on countershaft and seat
it against bearings (Fig. 152). Coat spacer with pe­
troleum jelly to hold it in place.
.BEARING
SPACER
FIFTH
GEAR
BEARINGS
J9221-236
Fig. 152 Countershaft Fifth Gear Bearing And
Spacer Installation
(5) Install synchro sleeve on hub of countershaft
fifth gear. Tapered side of sleeve faces front and flat
side faces rear (Fig. 153).
GEAR
SYNCHRO
SLEEVE
COUNTERSHAFT
FIFTH
GEAR
J9221-237
Fig. 153 Installing Synchro Sleeve On Countershaft
Fifth Gear Hub
(6) Install shift fork in synchro sleeve (Fig. 154).
(7) Install assembled fifth gear, synchro sleeve and
shift fork (Fig. 155). Align fork with shift lug rail
and align gear with bearings and countershaft. Start