DODGE TRUCK 1993 Service Repair Manual

21
- 60
G360
TRANSMISSION OVERHAUL

•
BLOCKER

Fig.
28
Removing
Blocker
Ring
From Gear
Output Shaft And
Gears
Inspect the shaft and gears for wear, or damage
(Fig. 30). Check for broken, or chipped gear teeth, SECOND
GEAR

Fig.
29
Removing
Roll
Pins
From Gear damaged synchro blocker rings, or worn galled bear­

ings.
Discoloration or shiny spots on gear teeth are a normal condition and do not indicate a need for re­
placement.
1 I

21 - 62 G360
TRANSMISSION
OVERHAUL

Synchronizers
And
Blocker
Rings

LEGEND
FOR OUTPUT SHAFT AND GEARTRAIN
COUNTER

GEAR

8

9

ho
11
12
13 14
15
16
17
18
19
20'
21
22

23'

24
25
'26 27
28
29 Front
Bearing

Input
Shaft

Blocker
Ring
(4th Gear)
Output
Shan
Pilot
Bearing

3-4
Synchro
Assembly
Blocker
Ring
(3rd gear)
Third
Gear

Third
Gear
Bearing
Snap
Ring

Spacer

Second
Gear

Second
Gear
Blocker
Ring
And Retaining
Pins
(3)

Second
Gear
Bearing

Output
Shaft
(2WD
version
shown)

1
-2
Synchro
Assembly

First
Gear
Bearing

First
Blocker
Ring
And Retaining
Pins
(3)

First
Gear

Spacer

Snap
Ring

Reverse
Gear
Bearing

Reverse
Gear

Blocker
Ring
(reverse gear)

Fifth-Reverse
Synchro
Assembly

Snap
Ring

Fifth
Gear
Bearing
(2-piece)

Blocker
Ring
(fifth
gear)

Fifth
Gear

Rear
Bearing
J9321-305

Inspect the synchro blocker rings (Fig. 30). Look
for evidence of wear or damage to the clutch material
on the rings. Also check the rings for cracks. Place
the rings on a flat surface to check for distortion.
The 1-2, 3-4 and fifth-reverse synchro hubs,
sleeves, struts and springs are serviced as assem­

blies.
If wear or damage is evident, it will be neces­ sary to replace the complete synchro assembly.

Counter
Gear
And Shaft Check the gear, shaft and bearings for wear or
damage (Fig. 31). Minor nicks or scratches on the
gear teeth can be smoothed off with an oilstone. Mi­
nor nicks or scratches on the shaft can be reduced and smoothed off with 320/400 grit emery cloth. The counter gear and shaft are not serviceable
components. If either part is damaged, it will be nec­
essary to replace the complete transmission assem­
bly.

Reverse
Idler
Components The reverse idler components consist of the gear,
shaft, thrust washers, pins, bearings and the shaft
bolt (Fig. 32). Clean and inspect the idler components. Replace
the gear if any teeth are chipped, or cracked. Replace
the shaft and bearings if galled, brinnelled, or se­
verely worn. The thrust washers can be reused but only if wear is not excessive and the washer notches are in good condition.
Replace the pins during overhaul. The pins should
not be reused. Also be sure the shaft bolt and case
REAR

BEARING

AND
SNAP
RING

COUNTER
GEAR

SHAFT

FRONT

BEARING
AND

SNAP
RING
J9321-308

Fig.
31
Counter
Gear
Components
threads are in good condition. The case threads can
be cleaned up with a tap, or repaired with Heli-Coil stainless steel thread inserts if necessary. Replace
the bolt if damaged.

THRUST

WASHER
REVERSE

IDLER

GEAR
BEARINGS

IDLER

SHAFT SHAFT

BOLT
THRUST

WASHER

SHAFT
PINS

J9321-309

Fig.
32 Idler Gear
Components

Bearings
And
Races
Inspect each bearing and race carefully. Check for
such conditions as spalling, wear, cracks, distortion,
or flat spotting of the rollers and races. Replace any
bearing or race if doubt exists about its condition.

Seals
And
Snap
Rings
Replace front and rear retainer seals and the coun­
tershaft front bearing cap. Do not reuse these parts.

•
G360
TRANSMISSION
OVERHAUL
21 - 63 The retainer seals have a small spring around the in­
ner part of the seal. Be sure each seal is installed
with this spring facing the case interior.
The snap rings should all be replaced. Eeusing
snap rings is not recommended.

Shift
Cover
Inspect the shift cover components (Fig. 33). The
only serviceable shift cover components are the shift
lever, lever retainer ring, snap ring, boot and clamp, and backup light switch.
If any of the shift forks, shift rails, or shift rail de­
tent parts are worn, or damaged, replace the shift cover assembly.
COVER 1-2 3-4

SHIFT

RAILS
J9321-310

Fig.
33 Shift
Cover
Assembly

TRANSMISSION
ASSEMBLY
AND
ADJUSTMENT

Assembly
Information
The only gasket in current G360 transmissions is
the shift cover gasket. All other sealing surfaces are
to be sealed with a coating of Mopar Gasket Maker, or Loctite 518.
Prior production G360 transmissions with the
early style gear case, were not equipped with a shift cover gasket. It is recommended that a gas­
ket be used on these transmissions during over­
haul or whenever the shift cover is removed during service. A gasket is available separately
or as part of the basic overhaul kit.
Apply Mopar Lock N' Seal, or Loctite 242 to bolt
threads before installation. These products will en­ sure proper fastener retention and sealing.
Lubricate the transmission components with Mopar
5W-30 engine oil or equivalent, during assembly. Pe­ troleum jelly can be used to hold parts in place and
prelubricate bearings and seal lips.
Do not use chassis grease, or similar products
on any component during assembly. Heavy lu­
bricating grease will plug the transmission oil
passages resulting in failure. Preload adjustments are required for the output
shaft and countershaft bearings. Preload is accom­
plished by the use of select fit shims. An accurate
vernier style depth gauge, depth micrometer, or dial indicator and suitable mounting stand are required
for measurement and adjustment. The procedure is described in the Bearing Preload Adjustment section.
ASSEMBLING OUTPUT SHAFT AND
GEARTRAIN

(1) Lubricate mainshaft, gears and synchro compo­
nents with Mopar 5W-30 engine oil. (2) Install blocker rings on first and second gears
as follows:
(a) Start roll pins into blocker rings and gears
with hammer (Fig. 34). (b) Seat roll pins with pin punch (Fig. 35). Be
sure roll pins are seated flush with surface of each
blocker ring. Do not drive pins below surface of
rings.

Fig.
34 Starting
Roll
Pins
In
First/Second
Gear
Blocker
Rings

(3) Install bearing in second gear and install sec­
ond gear on output shaft (Fig. 36).
(4) Install second gear thrust washer on output
shaft (Fig. 37). Washer is tight fit on shaft. Heat
washer in oven or use suitable tool to seat
washer on shaft.If washer is heated to ease instal­
lation, heat washer for no more than 5 minutes at

200°F.

21
- 64 1360
TRANSMISSION OVERHAUL

•

BLOCKER
RING

GEAR

J9321-297

Fig.
35 Seating
Roil
Pins
in
First/Second
Gear
Blocker
Rings

OUTPUT SHAFT-

SECOND
GEAR

J9321-298

Fig.
36
Second
Gear
Installation

INSTALLER
TOOL
THRUST

WASHER

SECOND
GEAR

J9321-299
Fig.
37
Second
Gear Thrust
Washer
Installation

(5)
Install second gear snap ring (Fig. 38). Snap
ring is select fit
part.
Use thickest snap ring that will fit

(6)
Install bearing in third gear. Then install gear
on output shaft (Fig. 39).
(7) Install synchro ring in third gear (Fig. 39).

(8)
Install 3-4 synchro assembly on output shaft
(Fig. 40). Side of synchro hub with long shoulder
goes to front of shaft and fits inside third gear.
Use suitable size pipe style tool to tap or press syn­
chro assembly into place.
SELECT

FIT

SNAP RING SECOND
GEAR

THRUST

WASHER

J9321-300
Fig.
38
Second
Gear
Snap
Ring
Installation

BLOCKER RING
THIRD

GEAR

J9321-301
Fig.
39 Third Gear And
Blocker
Ring
Installation

CAUTION:
Be
sure
the
third
gear blocker ring
is

aligned
with
the
synchro
hub
before seating
the
synchro
assembly. Failure
to
align
the
ring could result
in
damage
to the
blocker ring.
THIRD
GEAR
BLOCKER RING SYNCHRO
-INSTALLER
TOOL

3-4
SYNCHRO
ASSEMBLY

J9321-302

Fig.
40 Installing 3-4
Synchro
Assembly
(9)
Install pilot bearing on output shaft (Fig. 41).
Heat bearing in oven to ease installation, or use suit­ able tool to tap bearing into place.

(10)
Turn output shaft over so rear of shaft is fac­
ing upward.
(11)
Install 1-2 synchro assembly (Fig. 42). If new
synchro is being installed, it can be installed ei-

•

OUTPUT

SHAFT

"
PILOT
BEARING

J9321-303
Fig.
41 Output Shaft Pilot Bearing
Installation

ther way on shaft. If original synchro is being
reused, install synchro in same position as when
removed.

Fig.
42 Installing 1-2
Synchro
Assembly

(12) Install first gear bearing on mainshaft (Fig.

43). FIRST
GEAR
BEARING

J9321-306
Fig.
43 First Gear Bearing
Installation
G360
TRANSMISSION OVERHAUL
21 - 65
(13) Install first gear on mainshaft (Fig. 44). Work
gear back and forth until blocker ring seats in syn­
chro assembly.
Fig.
44 First Gear
Installation

(14) Install first gear thrust washer (Fig. 45).
Washer is tight fit on shaft. Either heat washer
in oven to ease installation, or use pipe tool or
brass drift to press washer onto shaft and against gear.
FIRST

GEAR Fig.
45 First Gear Thrust
Washer
Installation

(15) Install first gear snap ring (Fig. 46). Do not
overspread snap ring to install it. Also be sure snap ring is fully seated in shaft groove. Tap ring
into place with punch if necessary.
(16) Install bearing in reverse gear.
(17) Install reverse gear on mainshaft (Fig. 47).
(18) Install blocker ring in reverse gear (Fig. 47). (19) Install fifth-reverse synchro assembly (Fig.

48).
Be sure reverse gear blocker ring is aligned in synchro before proceeding. Use pipe tool to press syn­
chro into place if necessary.

21
- 66
G360
TRANSMISSION
OVERHAUL

SELECT

Fig.
46 Installing First Gear
Snap Ring
BLOCKER

Fig.
47
Reverse
Gear And
Blocker Ring
Installation

J9321-314
Fig.
48 Fifth-Reverse
Synchro
Installation (20) Install fifth-reverse synchro snap ring (Fig.

49).
This is a select fit snap ring. Use thickest snap ring that will fit In shaft groove and be sure snap ring is fully seated in shaft groove.
Move synchro into reverse position for snap ring se­ lection if necessary.

Fig.
49 Fifth-Reverse
Synchro Snap Ring
Installation
(21) Install fifth gear bearing halves on output
shaft (Fig. 50). Use petroleum jelly to hold bearing
halves in place. (22) Install blocker ring in fifth-reverse synchro
sleeve (Fig. 50). (23) Install fifth gear (Fig. 50).
SYNCHRO
SLEEVE
J9321-316

Fig.
50
Fifth
Gear,
Bearings
And
Blocker Ring
Installation (24) Install rear bearing on output shaft (Fig. 51).
Use suitable tool to seat bearing on shaft. (25) Verify correct gear installation. Refer to in­
stallation sequence shown in Figure 51.

6360
TRANSMISSION
OVERHAUL
21 - 67

3-4
THIRD
1-2
SYNCHRO
REVERSE
FIFTH

SYNCHRO
GEAR
ASSEMBLY
GEAR GEAR

SECOND
FIRST
FIFTH-REVERSE
GEAR GEAR
SYNCHRO
ASSEMBLY
J9321-287

Fig.
51 Output Shaft
Gea
REVERSE IDLER GEAR INSTALLATION
Different procedures are required for installing the
idler gear in early and new style gear cases.
The idler gear can be installed before installing the
counter gear in a new style gear case. However, the
counter gear must be installed before the idler gear
in an early style gear case.
Refer to the appropriate idler gear installation pro­
cedure during reassembly.

Reverse
Idler Installation (With New
Style
Gear
Case)
(1) Install reverse idler shaft part way into case
(Fig. 52).
Fig.
52 Idler Shaft Installed
Part
Way In
Case
fin
Installation
Sequence
(3) Position thrust washer at each end of idler gear
and install gear assembly in case (Fig. 53). Be sure
slots in thrust washers face outward as idler
gear roll pins fit in these slots.
(4) Align idler shaft pin holes and push idler shaft
into place in gear and washers.

IDLER
GEAR

Fig.
53 Idler Gear And Thrust
Washer
Installation
(5) Partially install idler shaft pins. Insert pins
only far enough to hold thrust washers in place. (6) Check idler gear thrust washer clearance (Fig.
54) as follows:
(a) Check clearance between each thrust washer
and idler gear with feeler gauge. (b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.). (2) Install bearings and spacer in reverse idler
gear (Fig. 32). Be sure spacer is installed between
bearings.

21
- 68
G360
TRANSMISSION OVERHAUL

• (c) If clearance is not within specified limits, re­
move idler gear and replace thrust washers. Use
new pins when gear and washers are reinstalled.

THRUST

WASHER
INSERT FEELER GAUGE HERE TO CHECK
CLEARANCE
Fig.
54
Checking
Idler Gear Thrust
Washer
Clearance
(7) Install idler shaft bolt (Fig. 55). Tighten bolt to
54 N*m (40 ft. lbs.) torque. J9321-317

Fig.
55 Idler Shaft
Bolt
Installation

(8) Tap idler shaft pins into place (Fig. 56).
J9321-318

Fig.
56 Idler Shaft Pin
Installation
REVERSE IDLER INSTALLATION (WITH
EARLY STYLE GEAR CASE)
(1) Install counter gear and shaft in case. Refer to
procedure in this section.
(2) Install idler shaft part way into case from
front. (3) Assemble and install reverse idler gear and
thrust washers. (4) Install rear pin in idler gear and shaft. Then
install front pin. (5) Check idler gear thrust washer clearance (Fig.
54) as follows:
(a) Check clearance between each thrust washer
and idler gear with feeler gauge.
(b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.).
(6) If clearance is not within specified limits, re­
move idler gear and replace thrust washers. Use new
pins when gear and washers are reinstalled.
COUNTER GEAR AND SHAFT INSTALLATION (1) Place gear case in upright position. Front bear­
ing retainer/input shaft bore should be facing up
(Fig. 57). (2) Slide counter gear into position in case (Fig.

57).

(3) Install front bearing and bearing snap ring on
countershaft (Fig. 57).
(4) Install countershaft in gear and seat shaft front
bearing in case (Fig. 57).
FRONT

BEARING COUNTERSHAFT
COUNTER GEAR

J9321-319
Fig.
57 Countershaft And Gear
Installation

(5) Install countershaft front bearing race in case
and on bearing (Fig. 58).

•

G360
TRANSMISSION
OVERHAUL
21 - 69

Fig.
58 Countershaft Front Bearing
Race
Installation
(6)
Install snap ring that retains countershaft front
bearing race in case bore (Fig. 59).
Fig.
59 Front Bearing
Race
Snap
Ring
Installation

(7) Install countershaft front bearing cap in case
bore (Fig. 60). Apply Mopar adhesive/sealant, or 3M industrial sealant
#800
around outer edge of
bearing cap before installation.

Fig.
60 Countershaft Front Bearing Cap
Installation
(8) Install rear bearing on countershaft. Then in­
stall bearing retaining snap ring.

OUTPUT
AND
INPUT
SHAFT
INSTALLATION
(1) Install new seal in front bearing retainer (Fig.

61).
Use socket or pipe tool to seat seal in retainer.
Be sure seal lip faces inward toward case inte­
rior.
(2) Install new front bearing on input shaft if nec­
essary. Use shop press to install bearing.
USE
SOCKET

AS
INSTALLER
TOOL

SEAL
SEATED
IN
RETAINER RETAINER
J9321-327

Fig.
61 Input Shaft
Seal
Installation

(3) Install input shaft. Rotate shaft so flats on
clutch teeth are facing downward. Then install shaft
in case.
(4) Install output shaft and geartrain assembly in
case (Fig. 62).

Fig.
62 Output Shaft And
Geartrain
Assembly
Installation

(5) Install front bearing race in gear case.
(6) Apply recommended sealer to front bearing re­
tainer flange surface. Then apply oil to lip of retainer
oil seal.
(7) Install front bearing retainer on case (Fig. 63).
It is not necessary to align retainer in any spe­ cial position. Oil channels and bolt holes in re­
tainer are symmetrical and can be installed in any position.
(8) Apply Mopar Lock N' Seal or Loctite 242 to
front bearing retainer bolts. Then install and tighten
bolts to 22-30 N«m (16-22 ft. lbs.) torque.
(9) Before proceeding, verify that countershaft
front bearing cap has been installed (Fig. 64).