3500 4x4 Pickup V10-488 8.0L Magnum (1994)
6.
Slide out the O.D. rail/fork assembly, clutch gear, synchronizer ring, and synchronizer assembly from the transmission.
7.
Discard the O.D. rail/fork assembly and the synchronizer assembly.
8.
Install new synchronizer assembly (P/N 4723002) onto the counter shaft.
9.
Install new O.D. shift fork (P/N 4773178) into the synchronizer sleeve and install new O.D. rail (P/N 4778216) through the fork and into the
transmission case. Install the new O.D. lug (P/N 4637692) onto the O.D. rail inside the transmission case.
10.
Install the synchronizer ring and clutch gear back onto the countershaft.
11.
Drive 2 new roll pins (P/N 4741362) into the fork and rail to join them together. Drive one roll pin into the lug and rail to join them together.
12.
Install new retainer ring (P/N 4637795) onto the countershaft.
13.
Clean mating surfaces of the extension housing, shift cover and gear case with a wax and grease remover such as Mopar Super Kleen (P/N
4318015).
14.
Apply Mopar Gasket Maker (P/N 4318083) to gear case, shift cover and extension housing surfaces.
15.
Align and install the extension housing on the gear case.
NOTE:
USE NEW EXTENSION HOUSING BOLTS. APPLY MOPAR LOCK N'SEAL P/N 4318031 OR LOCTITE 242 TO THE THREADS AND
TIGHTEN TO 54 N-m (40 ft.lbs.) TORQUE. USE A TWELVE POINT 10 mm SOCKET.
16.
Align and install the shift cover on the gear case. Apply Mopar Lock N' Seal (P/N 4318031) or Loctite 242 to threads and tighten bolts to 30 N-m
(265 in.lbs.) torque.
17.
Fill the transmission to the bottom edge of the fill plug hole with Mopar Manual Transmission Lubricant, (P/N 4637579) or Castrol Syntorq.
18.
Follow procedure listed in the appropriate service manual and install the transmission in the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 21-36-03-91 1994 BR 3.0 Hrs.
21-00-03-61 4x4 Equipped 1.7 Hrs.
21-00-03-60 Skid Plate Equipped 0.4 Hrs.
21-00-03-62 Two Piece Prop. Shaft 0.2 Hrs.
21-36-03-92 1992 - 1993 AD 2W/D 3.3 Hrs.
21-36-03-93 1992 - 1993 AD 4W/D 4.6 Hrs.
21-00-03-60 Skid Plate Equipped 0.3 Hrs.
21-00-03-62 Two Piece Prop. Shaft 0.2 Hrs.
21-00-03-63 Dual Exhaust Equipped 0.3 Hrs.
FAILURE CODE: P8 -New Part