Disassembly - MAINSHAFT W/ Input Shaft

Fig 1: Removing First Gear Idler Gear Using Special Tool

Courtesy of CHRYSLER LLC

Disassemble the geartrain housing. See DISASSEMBLY .
Mount the main shaft in a vise with protective jaws.
Remove first gear idler gear using special tool 938 and 1126.

Fig 2: Removing/Installing Reverse Gear Synchronizer Assembly
Courtesy of CHRYSLER LLC
Remove the reverse gear synchronizer assembly (1).

Fig 3: Removing/Installing Reverse Gear Synchronizer Ring & Idler Gear
Courtesy of CHRYSLER LLC
Remove the synchronizer ring (1) and idler gear (2) for reverse gear.

Fig 4: Removing/Installing First Gear Needle Bearing & Sleeve
Courtesy of CHRYSLER LLC
Remove first gear needle bearing (1) and sleeve (2).

Fig 5: Removing/Installing Thrust Washer, First Gear Idler Gear, & First Gear Idler Needle Bearing
Courtesy of CHRYSLER LLC
Remove the thrust washer (1), first gear idler gear (2), and first gear idler needle bearing (3).

Fig 6: Removing/Installing Friction Ring, Cone Ring, & Synchronizer Ring
Courtesy of CHRYSLER LLC
Remove the friction ring (1), cone ring (2), and the synchronizer ring (3).

Fig 7: Removing/Installing Locking Ring & 1st/2nd Gear Synchronizer
Courtesy of CHRYSLER LLC
Remove the locking ring (1) using pliers. Remove the 1st/2nd gear synchronizer using special tool 938 and 1126.

Fig 8: Removing/Installing Synchronizer Ring, Cone Ring, & Friction Ring
Courtesy of CHRYSLER LLC
Remove the synchronizer ring (1), cone ring (2), and friction ring (3).

Fig 9: Removing/Installing Second Gear Idler Gear & Needle Bearing
Courtesy of CHRYSLER LLC
Remove the second gear idler gear (1) and needle bearing (2).

Fig 10: Removing/Installing Main Shaft, Synchronizer Ring, Clutch Body & Cylindrical Roller Bearing
Courtesy of CHRYSLER LLC
Remove the main shaft (1) from the input shaft (2).
Remove the synchronizer ring (5) and the clutch body (4).
Remove the cylindrical roller bearing (3) from the input shaft (2).
Remove the input shaft (2) from the vise.

Fig 11: Removing/Installing Locking Ring, Synchronizer Cone & Clutch Body
Courtesy of CHRYSLER LLC
Clamp the main shaft (3) in the vise with input end up.
Remove the locking ring (1), pull off the synchronizer cone (2) and the clutch body using special tool 938 and 1126.

Fig 12: Removing/Installing Synchronizer Cone & Clutch Body
Courtesy of CHRYSLER LLC
Remove the synchronizer ring (1) and the clutch body (2).

Fig 13: Removing/Installing 6th Gear Idler Gear & Needle Bearing
Courtesy of CHRYSLER LLC
Remove the 6th gear idler gear (1) and needle bearing (2).
Remove the main shaft (3) from the vise.