Place mainshaft in Fixture 9648 mounted in a vise.Install second gear bearing (1) on mainshaft (2).

Install second gear (1) on bearing (2).

Install inner synchronizer friction ring (1) on second gear (2).

Install outer synchronizer friction ring (1) on second gear (2).

Install synchronizer blocker ring (1) on second gear (2).

Install 1-2 synchronizer hub (1) with Installer 8228 (2) and a press. Align hub detent openings with synchronizer rings.

Install 1-2 synchronizer hub (1) snap ring (2).Reuse original snap ring or thickest snap ring that will fit.

Install 1-2 synchronizer sleeve (1) and push to the bottom of the synchronizer hub (2).

Install 1-2 synchronizer detents, springs, and balls (2).

Install first gear blocker ring (1) into synchronizer hub (2).

Install first gear outer friction ring (1) into synchronizer hub (2).

Install first gear inner friction ring (1) into synchronizer hub (2).

Install first gear (1) and bearing (2). Then center 1-2 synchronizer sleeve on synchronizer hub.

Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.A bearing heater is used to assemble first gear thrust washer (1) and reverse gear bearing race (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 177 Celsius (212° Min - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.Heat first gear thrust washer (1) and reverse gear bearing race (2) with bearing heater.

Using welding gloves or tongs, install first gear thrust washer (1) then reverse gear bearing race (2).

Install reverse gear (1) and bearing (2).

Install reverse gear (1) synchronizer friction ring (2).

Install reverse gear synchronizer hub (1) on mainshaft with Installer W-262 (2) and a press. Align hub detent opening (3) with friction ring (4) lug.

Install reverse gear synchronizer hub (1) detents (2).

Install reverse gear (1) synchronizer sleeve (2) with tooth points pointing down and center sleeve on synchronizer hub.Remove mainshaft from Fixture 9648. Turn fixture over in the vise, then install opposite end of mainshaft in the fixture.

Install sixth gear (1) and bearing (2).

Install sixth gear synchronizer blocker ring (1) on sixth gear (2).

Install sixth gear synchronizer friction ring (1) on sixth gear (2).

Install 5-6 synchronizer hub (1) with Installer W-262 (2). Align hub detent opening (3) with friction ring lugs (4) and press hub on mainshaft.5-6 synchronizer hub center, is offset and must be install large offset down.

Install 5-6 synchronizer hub (1) snap ring (2).Reuse original snap ring or thickest snap ring that will fit.Install 5-6 synchronizer sleeve on hub (1).

Install countershaft bearing into rear housing with Installer 9643 (1) and Handle C-4171.

Install mainshaft bearing (1) into housing (2).Install bearing retainer and tighten bolts to 10 N·m (88 in. lbs.).

Install reverse idler gear (1) into housing (2).

Install idler gear (1) bearing (2) into gear.

Install idler gear (1) thrust washer (2) on idler gear.

Install idler gear (1) shaft support (2) into housing.

Install idler gear (1) shaft (2) with shaft bolt hole aligned with shaft support hole (3).

Install idler gear shaft bolt (1) into the housing (2) and tighten to 20 N.m (15 ft. lbs.).

Install 4x4 output shaft seal into rear housing (1) with Installer 9638 (2). Install 4x2 output shaft seal into rear housing with Installer 9635 and Installer 6448A.

Install input shaft bearing (1) on input shaft with the bearing retainer lip (2) facing fifth gear.

Install input shaft bearing (1) with Installer 6448A (2) and a press.

Install input shaft bearing (1) snap-ring (2).Reuse original snap ring or thickest snap ring that will fit.

Install input shaft seal with Installer 9635 (1) and Installer 6448A (2).

Install input shaft (1) with bearing (2) into housing.

Install input shaft (1) bearing retainers (2, 3) and tighten bolts to 10 N·m (88 in. lbs.).

Install input shaft retainer (1) and tighten bolts (2) to 9 N·m (80 in. lbs.).

Install countershaft bearing (1) into housing with bearing retainer lip (2) facing up.

Install countershaft bearing (1) retainers (2) and tighten bolts to 10 N·m (88 in. lbs.).

Install mainshaft (1) onto Build Fixture 9633 (2).

Install countershaft (1) onto Build Fixture 9633 (2).

Install oil slinger (3) on countershaft (2) between reverse (1) and first gear (4).

Install shift rails and forks (1) onto Fixture 9633 (2) and countershaft/mainshaft .

Install rear housing on mainshaft (1) with Installer 9636 (2).

Remove rear housing with mainshaft, countershaft and shift rails from fixture. Set assembly on rear housing with shafts pointing up.Install 5-6 synchronizer hub (1) detents, springs, and balls (2).

Install fifth gear synchronizer friction ring (1) on 5-6 synchronizer hub (2).

Install fifth gear blocker ring (1) on 5-6 synchronizer hub (2). Then hold blocker ring and center synchronizer sleeve.

Install input shaft roller bearing (1) on mainshaft (2).

Install shift rail (1) support plate (2) bolts and tighten to 8 N·m (71 in. lbs.).

Apply MOPAR® Gasket Maker to front housing.Install front housing (1) on rear housing (2) and tighten bolts to 28 N·m (20 ft. lbs.).

Install output shaft (1) snap ring (2) 4x4 only.

Install output shaft (1) seal (2) in rear housing with Installer 9638.

Through the shift tower opening (1) move two shift rails (2) forward to lock the transmission in two gear.

Install countershaft bolt (1) into the front housing (2) and tighten to 100 N·m (74 ft. lbs.).

Install countershaft plug (1) in front housing (2) with Installer 7828-A and Handle C-4171.

Move shift rails to neutral.To prevent plugging the transmission vent, apply just a thin film of MOPAR® Gasket Maker to shift tower mating surface.Install shift tower (1) and tighten bolts (2) to 14 N·m (10 ft. lbs.).

Install back up lamp switch (1) and bolt (2).