Disassembly And Assembly: Al6

DISASSEMBLY 

1. Place an oil drain pan under the drain plug and drain transmission fluid through the drain plug. Make sure the transmission is in the neutral position.

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   1 - Rear Output Oil Seal

   NOTE:

   Do not re-use the rear output oil seal, install a new seal if removal is necessary.

   NOTE:

   Do not damage the case surface.

2. Using a suitable tool, remove and discard the rear output oil seal.

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   1 - Output Shaft Lock Nut Stake

3. Using a suitable tool, carefully open the stakes on the output shaft lock nut. Remove the output shaft lock nut using the input shaft holding tool from (special tool #2051600210, Socket, Spline Input Shaft 21 Teeth) and the output shaft locknut socket (special tool #2051500210, Socket, Output Shaft 60 mm).

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   1 - Output Shaft Lock Nut

   2 - Rear Output Bearing

4. Remove the range position switch.

   Refer to SWITCH, RANGE POSITION, REMOVAL AND INSTALLATION .

5. Remove the output shaft lock nut and the rear output bearing. DISCARD  the output shaft lock nut.

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   1 - Rear Shift Fork Detent Plugs

6. Stand the transmission on the bell housing end. Remove the rear shift fork detent plugs with the balls and springs from the case.

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   1 - Shift Fork Detent Spring And Sleeve

   2 - Shift Fork Detent Springs

7. Remove the shift fork detent springs and shift fork detent balls from the front and rear case.
   NOTE:

   The shift fork detent spring and sleeve go to the very front, right side detent. The remaining shift fork detent springs and shift fork detent balls are all the same size and all the springs have the same tension.

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   1 - Rear Shift Fork Support Bolts

   2 - Left Side Front Shift Fork Pivot Bolt

8. Remove the rear shift fork support bolts from the left side of the transmission.

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   1 - Rear Shift Fork Support Bolts

   2 - Right Side Front Shift Fork Pivot Bolt

9. Remove the rear shift fork support bolts from the right side of the transmission.

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   1 - Rear Case Bolts

10. Remove the rear case bolts.

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    1 - Rear Case

11. Remove the rear case.
    NOTE:

    If necessary, lightly tap the rear case with a soft-faced hammer in the vicinity of the mating surface to separate it from the front case.

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    1 - Shim

    2 - Mainshaft Output Shaft Bearing

12. Remove the shim from the mainshaft output shaft. If necessary, remove the mainshaft output shaft bearing.
    NOTE:

    Use a press and bearing splitter to remove the mainshaft output shaft bearing from the output shaft, if replacement is necessary.

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    1 - 3-4 Shift Fork

    2 - 5-6 Shift Fork

13. Remove the 3-4 shift fork and the 5-6 shift fork.

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    1 - Mainshaft Output Shaft

    NOTE:

    When removing the output shaft, the needle bearing may stay inside (as shown) of the mainshaft output shaft.

14. Remove the mainshaft output shaft from the mainshaft.

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    1 - Input Shaft Rear Bearing

15. Remove the input shaft rear bearing.

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    1 - Oil Feed Tubes

16. Remove the plastic oil feed tubes from the case.

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    1 - Oil Separator Bolts

17. Remove the oil separator bolts.

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    1 - Shift Guide Plate Bolts

    2 - Shift Guide Plate

18. Remove the shift guide plate bolts. Remove the shift guide plate.

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    1 - Selector Lever Cover Assembly Bolts

    NOTE:

    If necessary, lightly pry around the selector lever cover with a suitable screw driver or pry bar in the vicinity of the mating surface to separate the selector lever cover assembly from the case.

19. Remove the selector lever cover assembly bolts.

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    1 - Selector Lever Cover Assembly

20. Remove the selector lever cover assembly.

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    1 - Inner Shift Lever Bolt

21. Remove and DISCARD  the inner shift lever bolt.

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    1 - Outer Shift Lever

22. Remove the outer shift lever.

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    1 - Inner Shift Lever

23. Remove the inner shift lever.

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    1 - Front Shift Fork Detent Plugs

24. Remove the front shift fork detent plugs with the balls and springs. DISCARD  the front shift fork detent plugs.

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    1 - Right Side Rear Shift Fork Support Bolts

    2 - Right Side Front Shift Fork Pivot Bolt

25. Remove and DISCARD  the right side front shift fork pivot bolt.

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    1 - Left Side Rear Shift Fork Support Bolts

    2 - Left Side Front Shift Fork Pivot Bolt

26. Remove and DISCARD  left side front shift fork pivot bolt.

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    1 - Reverse Idler Gear Side Bolt

27. Remove the reverse idler gear side bolt.

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    1 - Reverse Idler Gear Front Bolt

28. Remove the reverse idler gear front bolt.

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    1 - Socket, Allen 27 mm 2051400210

29. Remove the countershaft bearing snap ring service plug using (special tool #2051400210, Socket, Allen 27 mm).

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    1 - Front Input Shield Bolts

    2 - Front Input Shield

30. Remove the front input shield bolts and remove the front input shield.

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    1 - Countershaft Snap Ring

31. Place the transmission assembly horizontally on the bench. Expand the countershaft snap ring using a suitable pair of snap ring pliers and pull countershaft slightly to the rear to move snap ring from the groove.

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    1 - Mainshaft Snap Ring

    NOTE:

    Graphic shown without mainshaft installed for clarity.

32. Expand the mainshaft snap ring and pull mainshaft slightly to the rear to move the mainshaft snap ring from the groove in the bearing.

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    Mainshaft And Countershaft Subassembly

    NOTE:

    Hold the mainshaft and countershaft while pulling rearward to keep the snap rings from re-engaging.

33. Remove the mainshaft and countershaft subassembly from the case.

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    1 - Shift Select Shaft

    2 - 1-2 Shift Fork

34. Remove the shift select shaft.
35. Remove the 1-2 shift fork.

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    1 - Reverse Shift Fork And Shaft

36. Remove the reverse shift fork and shaft.

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    1 - Reverse Idler Gear

37. Remove the reverse idler gear.

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    1 - Oil Slinger

    2 - Notches

38. Remove the oil slinger from the front case.

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    1 - Front Seal

39. Remove the front seal.
40. Remove the front input shaft seal from the case using (special tool #2051800210, Remover, Seal Input Shaft).

ASSEMBLY 

1. Thoroughly clean the case, the case mating surfaces and control cover using parts cleaner or equivalent, then fine scuff the pads.

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   1 - Front Seal

2. Install the front case seal into the groove. Verify the seal is seated in the channel.

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   1 - Oil Slinger

   2 - Notches

3. Install the oil slinger in the case bore using petroleum jelly or transmission assembly lube to hold it in place on the case half. Verify the notches are seated in the relief in the bore.

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   1 - Oil Separator

   2 - Countershaft

4. Lay the countershaft in the oil separator so it protrudes from the case enough to build the assembly before sliding it in place.

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   1 - Reverse Shift Fork And Shift Rail

5. Loosely install the reverse shift fork and shift rail into the transmission case. Verify the shift fork is seated in the groove of the sleeve in the correct orientation.

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   1 - Mainshaft

6. Loosely install the mainshaft on top of the countershaft.

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   1 - Reverse Idler Gear

7. Install the reverse idler gear loosely in the case.

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   1 - Reverse Idler Gear

   2 - 1-2 Shift Fork

   3 - Oil Separator

8. Verify that the reverse idler gear is installed prior to installing the 1-2 shift fork. Install the 1-2 shift fork with the shoes oriented in the groove of the sleeve. There should be clearance in the slot on the oil separator for free movement of the shift fork.

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   1 - Shift Select Shaft

   2 - 1-2 Shift Fork

9. Install the shift select shaft (1).

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   1 - Tabs

10. Make sure the tabs are seated correctly for the 1-2 shift fork.

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    1 - Shaft Bearings

11. Align the shaft bearings to the bores.

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    Shaft Installation

12. With the transmission laying on the bench, gently start locating the shafts into the case bores until the bearings are located in their respective bores and pulled up to the snap rings.
    NOTE:

    Verify the shift shaft and shift forks remain aligned while sliding the countershaft and mainshaft into the case bores.

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    1 - Countershaft Snap Ring

13. Open the countershaft snap ring using a suitable pair of snap ring pliers. Gently slide the countershaft into the snap ring until the snap ring aligns with the groove on the bearing.

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    1 - Mainshaft Snap Ring

    NOTE:

    Graphic shown without mainshaft installed for clarity.

14. Stand the transmission vertically on the bell-housing end while supporting the shafts. Using a suitable pair of snap ring pliers, open the mainshaft snap ring and seat the bearing in the bore with the snap ring in the groove on the bearing.

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    1 - Left Side Rear Shift Fork Support Bolts

    2 - Left Side Front Shift Fork Pivot Bolt

15. Install the NEW  front left side shift fork pivot bolt.

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    1 - Right Side Rear Shift Fork Support Bolts

    2 - Right Side Front Shift Fork Pivot Bolt

16. Install the NEW  right side front shift fork pivot bolt and torque both shift fork pivot bolts to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Reverse Idler Gear Front Bolt

17. Install the reverse idler gear front bolt with a NEW  washer and hand tighten.

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    1 - Reverse Idler Gear Side Bolt

18. Install the reverse idler gear side bolt with a NEW  washer and tighten both reverse idler bolts to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Front Shift Fork Detent Plugs

19. Install the front shift fork detent balls, springs and NEW  plugs into the top 2 bores (case standing on bell housing). Install the long sleeve and spring to the bottom front bore with the NEW  plug and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Shift Fork Detent Spring And Sleeve

    2 - Shift Fork Detent Springs

20. The shift fork detent spring and sleeve go to the very front, right side detent. The remaining shift fork detent springs and shift fork detent balls are all the same size and all the springs have the same tension.

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    1 - Inner Shift Lever

21. Install the inner shift lever.

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    1 - Outer Shift Lever

22. Install the outer shift lever.

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    1 - Inner Shift Lever Bolt

23. Install the NEW  inner shift lever bolt and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Selector Lever Cover Assembly

24. Clean the selector lever cover assembly and the mating surface on the case using a plastic scraper and brake clean. Apply a 1/8 inch bead of Mopar® orange RTV to the sealing surface of the selector lever cover assembly.

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    1 - Selector Lever Cover Assembly Bolts

25. Position the select lever cover assembly to the transmission, then install the bolts and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Shift Guide Plate Bolts

    2 - Shift Guide Plate

26. Install the shift guide plate. Install the shift guide plate bolts and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Oil Separator Bolts

27. Install the oil separator bolts and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Oil Feed Tubes

28. Install the plastic oil feed tubes.

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    1 - Oil Feed Locating Tip

    2 - Oil Feed Holes

29. Verify the tubes are seated in the oil feed locating tip and holes in the front case half.

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    1 - Oil Feed Tubes

    2 - Oil Feed Tubes Upper Guide Hole

30. Verify the oil feed tube is seated in the upper guide hole.

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    1 - 3-4 Shift Fork

    2 - 5-6 Shift Fork

31. Install the 3-4 shift fork and the 5-6 shift fork on the mainshaft.

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    1 - Input Shaft Rear Bearing

32. Install the input shaft rear bearing.

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    1 - Installer, Bearing Output Shaft 2052300210

    2 - Mainshaft Output Shaft Bearing

    3 - Mainshaft Output Shaft

33. If replacing the mainshaft output shaft bearing, press the NEW  mainshaft output shaft bearing on the mainshaft output shaft using (special tool #2052300210, Installer, Bearing Output Shaft).

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    1 - Mainshaft Output Shaft

34. Install the mainshaft output shaft to the mainshaft. Make sure the synchronizer is fully seated.

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    1 - Shim

    2 - Mainshaft Output Shaft Bearing

35. Install the output shim to the mainshaft output shaft.

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    1 - Seal

36. Install the seal into the rear case half. Verify the seal is fully seated in the groove.

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    1 - Rear Case

37. Clean both case half mating surfaces. Apply a 1/8 inch bead of Mopar® orange RTV around the stationary case half mating surface. Operate the selector lever and shift into 2nd gear. Install the rear case.
    NOTE:

    Before installing the rear case, verify the shift select shaft and reverse fork shaft are standing vertical. In addition, verify that the 3-4 fork and 5-6 fork are in the correct position.

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    1 - Rear Shift Fork Support Bolts

    2 - Right Side Front Shift Fork Pivot Bolt

38. Install the right side rear shift fork support bolts.

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    1 - Rear Shift Fork Support Bolts

    2 - Left Side Front Shift Fork Pivot Bolt

39. Install the left side rear shift fork support bolts and tighten both side shift fork support bolts to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - cover plug hole

40. Remove the cover plug and verify the oil feed tube is aligned to the cover plug hole. Reinstall the cover plug and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Rear Case Bolts

41. Install the rear case bolts and tighten to the proper. Refer to TORQUE SPECIFICATIONS  . Tighten the bolts in a crisscross pattern.

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    1 - Rear Shift Fork Detent Plugs

42. Install the rear shift fork detent balls, springs and plugs to the case and tighten the shift fork detent plugs to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Socket, Allen 27 mm 2051400210

43. Install the countershaft bearing snap ring service plug using (special tool #2051400210, Socket, Allen 27 mm) and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Installer, Seal Input Shaft 2052000210

44. Install a

    NEW 

    front input seal using

    (special tool #2052000210, Installer, Seal Input Shaft).

    NOTE:

    Verify the front input seal installed depth is within specification. Refer to TORQUE SPECIFICATIONS  .

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    1 - Front Input Shield Bolts

    2 - Front Input Shield

45. Install the input shaft sleeve and the input shaft sleeve bolts and tighten to the proper. Refer to TORQUE SPECIFICATIONS  .
46. Install the range position switch.

    Refer to SWITCH, RANGE POSITION, REMOVAL AND INSTALLATION .

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    1 - Output Shaft Lock Nut

    2 - Rear Output Bearing

47. Install the rear output bearing and the NEW  output shaft lock nut. Use (special tool #2051600210, Socket, Spline Input Shaft 21 Teeth) to hold the input shaft and (special tool #2051500210, Socket, Output Shaft 60 mm) to tighten the nut to the proper. Refer to TORQUE SPECIFICATIONS  .

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    1 - Output Shaft Lock Nut Stake

48. Stake the nut to the locknut groove on the output shaft.

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    1 - Installer, Seal Output Shaft 2051900210

49. Install a NEW  rear oil seal using (special tool #2051900210, Installer, Seal Output Shaft).
    NOTE:

    Verify the rear output seal installed depth is within specification. Refer to TORQUE SPECIFICATIONS  .