SM 108

2012 MANUAL TRANSMISSION
G56 - Service Information - Ram Pickup
DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - MANUAL TRANSMISSION - G56
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or incorrect
lubricant level check.
Rear transmission leaks will be from the oil seals or component mating surfaces.
Front transmission leaks will be from the front input shaft retainer seal. Lubricant may drip from the clutch
housing after extended operation. If leak is severe, it may contaminate the clutch disc.
Lubricant level check can only be made when the vehicle is level and allowing the lubricant to settle for a
minute before checking. This will ensure an accurate check and avoid an under or overfill condition.
HARD SHIFTING
Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants. This will cause
noise, excessive wear, internal bind, and hard shifting. Substantial lubricant leaks can result in gear, shift rail,
synchro, and bearing damage. The first indications of component damage is usually hard shifting and noise.
Shift component damage, clutch adjustment, worn pressure plate or disc are also causes of increased shift effort.
If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchronizer rings can
cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings
may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine
that is audible, but generally only at extreme speeds.
Severe, highly audible transmission noise is generally the initial indicator of a lubricant problem. Insufficient,
improper or contaminated lubricant will promote rapid wear of gears, synchronizer rings, shift rails, forks and
bearings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAIN AND FILL
Fig. 1: Drain Plug
Courtesy of CHRYSLER GROUP, LLC
1. Raise and support vehicle.

2. Remove drain plug (1) on transmission (2) and drain fluid.
3. Install drain plug and tighten to 57 N.m (42 ft. lbs.).
Fig. 2: Fill Plug

4. Remove fill plug (1) on right side of the transmission (2).

5. Fill transmission to approximately 16 mm (0.625 inch) from the bottom of the fill hole.
6. Install fill plug and tighten to 57 N.m (42 ft. lbs.).
ADJUSTMENTS
ADJUSTMENTS
CAUTION: This procedure must be performed any time a mainshaft, countershaft or

input shaft bearing or shaft is replaced. Failure to follow these instructions
will result in damaging the transmission.
MAINSHAFT
Fig. 3: Identifying Mainshaft Case Measurement

1. Set mainshaft, input shaft and countershaft into the rear housing. Rotate the shafts to seat bearing in rear
housing.
2. Remove mainshaft bearing cup, shims and oiler washer from the front housing.
3. Position Measurement Fixture (special tool #9592, Fixture, End Play) (1) on front housing over the
mainshaft bearing cup bore.
4. Loosen the knob (2) on the fixture and lower the shaft onto the mainshaft bearing cup (3) bore shoulder.
Then tighten the knob to hold the shaft.
5. Remove the fixture from the front housing.
Fig. 4: Identifying Fixture, Knob & Mainshaft Bearing
6. Place mainshaft shaft bearing cup on mainshaft bearing.

7. Position Fixture (special tool #9592, Fixture, End Play) (1) on rear housing over the mainshaft bearing
(2).
8. Loosen the knob (3) on the fixture (1). This will allow the rod plunger to drop down on the bearing cup.
Fig. 5: Measuring Gap Between Fixture Shaft & Fixture Plunger

9. Measure the gap (1) between the fixture shaft (2) and the fixture plunger (3). Repeat measurement on the
opposite side of the mainshaft cup and bearing. The average of the two measurement, will be the size of
the mainshaft select shim.
10. Install new oil supply washer and select shim in front housing mainshaft bearing cup bore and install
bearing cup.
COUNTERSHAFT
Fig. 6: Countershaft Case Measurement

1. Remove countershaft bearing cup and shims from the rear housing.
2. Position Fixture (special tool #9592, Fixture, End Play) (1) on rear housing over the countershaft bearing
cup bore.
3. Loosen the knob (2) on the fixture and lower the shaft onto the countershaft bearing cup (3) bore
shoulder. Then tighten the knob to hold the shaft.
4. Remove the fixture from the front housing.
Fig. 7: Positioning Fixture 9592 On Rear Housing Over The Countershaft Bearing
5. Place countershaft bearing cup on countershaft bearing.

6. Position Fixture (special tool #9592, Fixture, End Play) (1) on rear housing over the countershaft bearing
(2).
7. Loosen the knob (3) on the fixture (1). This will allow the rod plunger to drop down on the bearing cup.
Fig. 8: Measuring Gap Between Fixture Shaft & Fixture Plunger

8. Measure the gap (1) between the fixture shaft (2) and the fixture plunger (3). Repeat measurement on the
opposite side of the countershaft cup and bearing. The average of the two measurements, will be the size
of the countershaft select shim.
9. Install select shim in front housing countershaft bearing cup bore and install bearing cup.
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.

Fill Plug 57 42 -
Drain Plug 57 42 -
Front to Rear Housing 58 43 -
Bolts
Input Shaft Retainer
23 17 -
Bolts
Shift Tower bolts 23 17 -
5-6 Shift Fork Bolts 58 43 -
Shift Rail Support bolts 58 43 -
Reverse Idler Gear Shaft
58 43 -
Bolt
P.T.O. Cover Bolts 58 43 -
Clutch Release Pivot Ball 22 16 -
4X2 Output Shaft Flange
260 190 -
Bolt
NOTE: Two different transmission gear ratios are used. To verify, look at the last two
letters on the transmission bar code label. The last two letters on the bar code
located on the right side of the transmission will be AD or AE.
AD - GEAR RATIO
GEAR RATIO
FIRST 6.29
SECOND 3.48
THIRD 2.10
FOURTH 1.38
FIFTH 1.00
SIXTH 0.79
REVERSE 5.74
AE - GEAR RATIO
GEAR RATIO
FIRST 5.94
SECOND 3.28
THIRD 1.98
FOURTH 1.31
FIFTH 1.00
SIXTH 0.74
REVERSE 5.42
REMOVAL
REMOVAL
Fig. 9: Identifying Inner Boot, Shift Tower & Transmission

1. With vehicle in neutral, position vehicle on hoist.

2. Disconnect battery negative cable.
3. Remove shift boot bezel and slide boot upward on shift lever extension.
4. Remove inner boot (1) from floor pan and remove shift tower (2) from transmission (3).
5. Remove 4WD shift boot if equipped.
Fig. 10: Drain Plug
6. Remove skid plate, if equipped.

7. Remove drain plug (1) from transmission (2) and drain fluid.
Fig. 11: Marking Manual Transmission Flange & Propeller Shaft Flange
8. Mark transmission flange (1) and propeller shaft (2) for installation reference before removing propeller
shaft. If 4x4 equipped mark transfer case and front propeller shaft before removing shaft.
Fig. 12: Slave Cylinder & Mounting Nuts

9. Disconnect harness from clips on transmission housing.

10. Remove transfer case linkage 4x4 equipped.
11. Remove transfer case mounting nuts and remove transfer case 4x4 equipped.
12. Remove slave cylinder (1) mounting nuts (2) and remove cylinder.
Fig. 13: Exhaust Bracket

13. Remove exhaust bracket (1) bolts and remove bracket on diesel engine.
14. Remove exhaust pipe. Refer to PIPE, EXHAUST, REMOVAL .
Fig. 14: Securing Transmission To Transmission Jack

15. Support engine with adjustable jack stand and wood block.
16. Support and secure transmission (1) to a transmission jack (2) with safety chains.
Fig. 15: Transmission Mount Nuts

17. Remove transmission mount nuts (1) from crossmember (2).
Fig. 16: Crossmember & Bolts

18. Remove rear crossmember bolts (2) and remove crossmember with transmission mount.
19. Remove bolts attaching transmission to the engine.
20. Move transmission rearward until input shaft is clear of clutch disc and pressure plate. Then lower jack
and remove transmission from under vehicle.
DISASSEMBLY
DISASSEMBLY
Fig. 17: Shift Tower & Bolts
1. Set transmission on rear housing.

2. Remove shift tower bolts (1) and shift tower (2).
Fig. 18: Shifter Boot

3. Pry off shift tower boot (1) with a screw driver (2).
Fig. 19: Flange Bolt

4. On 4x2 transmissions shift two shift rails to lock the transmission in two gears. Then remove output shaft
flange (1) bolt (2). Remove flange from output shaft with a two jaw puller if necessary.
Fig. 20: Aligning Shift Rails In Neutral Position

5. Through shift tower opening (1) align shift rails in neutral position (2) and install tie strap to shift rails.
Fig. 21: 5-6 Shift Fork Pivot Pin

6. Remove 5-6 shift fork pivot pin (1) from both sides of the case.
Fig. 22: Reverse Idler Shaft Pin
7. Remove reverse idler gear shaft pin (1) from the rear housing (2).
Fig. 23: Back-Up Lamp Switch

8. Remove back-up lamp switch (1) bolt (2) and remove switch.
Fig. 24: Front & Rear Housing
9. Remove transmission housing bolts.

10. Tap housing with dead-blow hammer and lift front housing (1) off rear housing (2).
Fig. 25: 5-6 Shift Fork

11. Remove 5-6 shift fork (1) from shift rail and synchronizer sleeve (2).
Fig. 26: Removing Input Shaft From Mainshaft
12. Remove input shaft (1) from mainshaft (2).
Fig. 27: Reverse Idler Shaft

13. Thread a M6x1bolt (1) into the reverse idler gear shaft (2) and pull shaft out of rear housing.
Fig. 28: Sliding Reverse Idler Gear To Side Of Case
14. Slide reverse idler gear (1) off to the side of the case (2) for disassembly clearance.
Fig. 29: Countershaft, Mainshaft & Shift Rails

15. Lift and tilt countershaft (1) then remove mainshaft with shift rails (2).
16. Remove countershaft.
Fig. 30: Reverse Idle Gear
17. Remove reverse idler gear (1) from rear housing (2).
MAINSHAFT
Fig. 31: Identifying Shift Forks

1. Remove reverse (1) 1-2 (2) and 3-4 (3) shift forks and shift rails as an assembly from mainshaft.
Fig. 32: Fifth Gear Synchronizer
2. Position mainshaft in Fixture (special tool #9605, Fixture) mounted in a vise with sixth gear up.
3. Remove fifth gear synchronizer rings (1) from 5-6 synchronizer hub (2).
Fig. 33: 5-6 Synchronizer Springs

4. Slowly pull 5-6 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).
Fig. 34: 5-6 Synchronizer Sleeve
5. Remove 5-6 synchronizer sleeve (1) from hub (2).
Fig. 35: Mainshaft Bearing Snap Ring

6. Remove mainshaft bearing (1) snap ring (2).

Fig. 36: Removing Mainshaft Bearing, 5-6 Synchronizer Hub & 6th Gear Synchronizer Rings
7. Remove mainshaft bearing (1), 5-6 synchronizer hub (2), and sixth gear synchronizer rings (3) with three
jaw puller (4). Position puller jaws under sixth gear synchronizer rings (3).
Fig. 37: Sixth Gear & Bearing

8. Remove sixth gear (1) and bearing (2) from mainshaft (3).
Fig. 38: Fourth Gear Snap Ring
9. Remove fourth gear (1) snap ring (2).
Fig. 39: 4th Gear Thrust Washer & Synchronizer Stop Ring
10. Remove fourth gear thrust washer (1) with Puller (special tool #9594, Remover, Gear & Synchro).
Position puller under fourth gear synchronizer stop ring (2).
Fig. 40: Removing 4th Gear Thrust Washer
11. Install Bridge (special tool #938, Bridge) (1) into Puller (special tool #9594, Remover, Gear & Synchro)
(2) and remove fourth gear thrust washer (3).
Fig. 41: Fourth Gear & Bearing

12. Remove fourth gear (1) and bearing (2).

Fig. 42: Fourth Gear Synchronizer Rings
13. Remove fourth gear synchronizer rings (1) from 3-4 synchronizer hub (2) and mark installation reference.
Fig. 43: 3-4 Synchronizer Sleeve & Springs

14. Slowly pull 3-4 synchronizer sleeve (1) up on hub enough to remove detents and springs (2).
15. Remove 3-4 synchronizer sleeve (1) from hub.
Fig. 44: 3-4 Synchronizer Hub Snap Ring
16. Remove 3-4 synchronizer hub (1) snap ring (2).
Fig. 45: 3-4 Synchronizer Hub & Third Gear Synchronizer Rings
17. Remove 3-4 synchronizer hub (1) and third gear synchronizer rings (2). Mark components for installation
reference.
Fig. 46: Third Gear & Bearing
18. Remove third gear (1) and bearing (2).
Fig. 47: Reverse Gear & Synchronizer Sleeve

19. Turn mainshaft and Fixture (special tool #9605, Fixture) and secured in vise.
20. Remove 4x4 mainshaft snap ring.
21. Remove reverse gear synchronizer sleeve (1) from reverse gear (2) synchronizer hub.
Fig. 48: Reverse Gear Synchronizer Hub & Detents
22. Remove reverse gear synchronizer hub (1) detents (2).
Fig. 49: Removing Mainshaft Bearing

23. Remove mainshaft bearing (1) with Bridge (special tool #938, Bridge) (2) and bearing Puller (special tool
#9647, Puller) (3).
Fig. 50: Positioning Puller Behind Reverse Synchronizer Hub & Outer Blocker Ring
24. Position puller (1) behind reverse synchronizer hub and outer blocker ring (2).
Fig. 51: Reverse Gear & Bearing

25. Remove reverse gear (1) and bearing (2).

Fig. 52: Reverse Bearing Race & Thrust Washer
26. Remove reverse gear bearing race (1) and thrust washer (2). Use Puller (special tool #9646, Puller, Gear)
and Bridge (special tool #938, Bridge) on first gear (3) to pull off reverse gear bearing race (1) and thrust
washer (2).
Fig. 53: First Gear & Bearing

27. Remove first gear (1) and bearing (2).

Fig. 54: First Gear Synchronizer Rings & 1-2 Synchronizer Hub
28. Remove first gear synchronizer rings (1) from 1-2 synchronizer hub (2) and mark for installation
reference.
Fig. 55: 1-2 Synchronizer Sleeve & Springs

29. Slowly pull 1-2 synchronizer sleeve (1) up on hub (2) enough to remove detents and springs (3).
30. Remove 1-2 synchronizer hub (1) snap ring (2) and remove hub with second gear synchronizer rings.
Mark components for installation reference.
Fig. 57: 2nd Gear

31. Remove second gear (1) from mainshaft (2).

Fig. 58: 2nd Gear Bearing
32. Remove second gear bearing (1) from mainshaft (2).
COUNTERSHAFT
Fig. 59: Removing Countershaft Rear Bearing

NOTE: Bearings are the only component serviced on the countershaft.
1. Remove countershaft rear housing bearing with Puller (special tool #6444, Puller, Bearing/Gear) (1), Plug
(special tool #8513A, Insert, Crankshaft) (2), Puller Jaws (special tool #9597, Remover, Bearing) (3),
Puller Collar (special tool #6444-8, Sleeve) (4), Puller Rods (special tool #6444-3, Rod, Long) and Puller
Flange (special tool #6444-1, Puller, Base). Position Puller Jaws (special tool #9597, Remover, Bearing)
around bearing and puller flange. Position puller collar around the puller jaws. Tighten the puller bolt and
remove countershaft bearing.
2. Remove countershaft first/reverse gear bearing oil slinger from countershaft.
Fig. 60: Removing Countershaft Front Housing Bearing

3. Remove countershaft front housing bearing with Puller (special tool #6444, Puller, Bearing/Gear) (1),
Puller Collar (special tool #6444-8, Sleeve) (2), Puller Jaws (special tool #9597, Remover, Bearing) (3),
Puller Rods (special tool #6444-3, Rod, Long) and Puller Flange (special tool #6444-1, Puller, Base).
Position puller jaws around bearing and puller flange. Position puller collar around the puller jaws.
Tighten the puller bolt and remove countershaft bearing.
INPUT SHAFT
Fig. 61: Input Shaft & Mainshaft Bearing Seal
1. Position input shaft (1) mainshaft bearing seal (2) in a vice then twist input shaft (1) out of the seal (2).
Fig. 62: Removing Input Shaft Bearing

2. Remove input shaft (1) bearing with Puller (special tool #C-293-PA, Puller, Press) (2) and Adapters
(special tool #C-293-47, Block Set, Puller) (3).
3. Remove input shaft mainshaft bearing gasket.
REAR HOUSING
Fig. 63: Removing Countershaft & Mainshaft Bearing Cups
1. Remove countershaft bearing cup and mainshaft bearing cup with Puller (special tool #9593, Remover,
Bearing Cup) (1) installed in cup (2).
Fig. 64: Identifying Remover, Puller & Remover Nut

2. Install Remover (special tool #8915, Brace) (1) on puller (2) and tighten remover nut (3) to pull cups out
of the housing.
Fig. 65: Output Shaft Seal
3. Remove output shaft seal (1) from housing (2) with seal pick.
FRONT HOUSING
Fig. 66: Front Housing Cup Remover

1. Remove countershaft bearing cup and mainshaft bearing cup with Puller (special tool #9593, Remover,
Bearing Cup) (1) installed in cup (2).
Fig. 67: Pulling Front Housing Cups
2. Install Remover (special tool #8915, Brace) (1) on puller (2) and tighten remover nut (3) to pull cups out
of the housing. Then remove end-play shims from bearing bores and oil supply washer from mainshaft
bearing bore.
Fig. 68: Input Shaft Seal Retainer & Bolts

3. Remove input shaft retainer (1) bolts (2) and remove retainer.
Fig. 69: Input Shaft Seal & Retainer Bore
4. Remove input shaft seal (1) from retainer bore (2) with a seal pick.
CLEANING
CLEANING
Clean gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not
use acid or corrosive base solvents. Dry all parts except bearings with compressed air.
Clean shaft bearings with a mild solvent such as MOPAR® degreasing solvent, Gunk® or similar solvents. Do
not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop
towels.
INSPECTION
INSPECTION
Fig. 70: Identifying Countershaft Teeth & Bearings
NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and
polished out with crocus cloth.
Bearings: Inspect for worn, chipped, cracked, flat-spotted or brinnelled.
Gears: Inspect for worn, chipped or cracked teeth. Inspect bearing surfaces for wear or flat-spotted.
Mainshaft: Inspect for worn splines, snap ring grooves and threads.
Countershaft: Inspect all gears for worn, chipped or cracked teeth (1). Inspect all bearings (2) and bearing
surfaces for ware or flat-spotted. The countershaft is serviced as an assembly, except for bearings.
Oil slinger: Inspect first/reverse oil slinger for cracks.

Fig. 71: Identifying Input Shaft, Bearing, Fifth Gear & Splines
Synchronizer components: Inspect for worn, chipped or cracked teeth and burned or flaking off friction
material. Synchronizer are serviced as an assembly.
Input Shaft: Inspect shaft (1), bearing (2) surfaces for wear or flat-spotted. Inspect fifth gear (3) for worn,
chipped or cracked teeth. Inspect splines (4) for wear and chips.
Fig. 72: Identifying Shift Forks & Rails

Shift forks and Rails: Inspect shift forks (1) and shoes for wear and distortion. Check fit of fork shoes in
synchronizer sleeve to ensure parts fit and work smoothly. Inspect shift rails (2), for wear and distortion. 5-6
shift fork shoes (3) are serviced separately. Inspect 5-6 shift fork pivot pin O-rings.
Fig. 73: Identifying Front Shift Rail Guide & Bearing Oil Baffle
Front Housing: Inspect sealing and mating surfaces are free of burrs and nicks. Inspect alignment dowels are
tight and in good condition. Inspect shift rail guide (1) for wear and verify bearing oil baffle (2) is not bent or
damaged.
Fig. 74: Identifying Rear Shift Rail Guide & Bearing Oil Baffle
Rear Housing: Inspect sealing and mating surfaces are free of burrs and nicks. Inspect shift rail guide (1) for
wear and verify bearing oil baffle (2) is not bent or damaged.
Fig. 75: Identifying Bearing Slide Surface & Sealing Surface

Input Retainer: Inspect release bearing slide surface (2) and sealing surface.
ASSEMBLY
ASSEMBLY
WARNING: Use welding gloves or tongs when handling heated components. Failure
to follow these instructions will result in personal injury.
CAUTION: A bearing heater is used to assembly some components. Use only a

bearing heater/hot plate and follow manufacture's instructions. Heat
components to 100° - 150° Celsius (212° Min. - 300° Max Fahrenheit). Never
use an open flame to heat components. Never leave components on heater
for and 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.
INPUT SHAFT
Fig. 76: Heating Bearing
1. Heat input shaft bearing (1) on bearing heater (2) to a maximum of 150 Celsius (300° Fahrenheit).
Fig. 77: Input Shaft & Bearing

2. Using welding gloves or tongs, install bearing (2) on input shaft (1).
Fig. 78: Input Shaft Mainshaft Bearing Seal
3. Push input shaft mainshaft bearing seal (1) on the end of fifth gear (2).
COUNTERSHAFT

1. Install first/reverse gear bearing oil slinger on the rear housing end of the countershaft.
2. Heat rear housing countershaft bearing (1) on bearing heater (2) to a maximum of 150 Celsius (300°
Fahrenheit).
Fig. 80: Installing Countershaft Bearing On Countershaft
3. Using welding gloves or tongs, install countershaft bearing (1) on countershaft (2).

4. Heat front housing countershaft bearing (1) on bearing heater (2) to a maximum of 150 Celsius (300°
Fahrenheit).
Fig. 82: Installing Front Housing Countershaft Bearing On Countershaft
5. Using welding gloves or tongs, install front housing countershaft bearing (1) on countershaft (2).
MAINSHAFT
Fig. 83: 2nd Gear Bearing

1. Position mainshaft in Fixture (special tool #9605, Fixture) mounted in vise.

2. Install second gear bearing (1) on mainshaft (2).
Fig. 84: 2nd Gear
3. Install second gear (1) on mainshaft (2).
Fig. 85: Installing Second Gear Stop Ring

4. Install second gear stop ring (1) with teeth pointing up on second gear (2).
Fig. 86: Installing Second Gear Inner Friction Ring
5. Install second gear inner friction ring (1) on stop ring (2).
Fig. 87: Installing Second Gear Outer Friction Ring

6. Install second gear outer friction ring (1) on stop ring (2).
Fig. 88: Installing Second Gear Blocker Ring
7. Install second gear blocker ring (1) on stop ring (2).
Fig. 89: Installing 1-2 Synchronizer Hub

8. Install 1-2 synchronizer hub (1) on mainshaft and synchronizer rings (2).
Fig. 90: Installing 1-2 Synchronizer Hub Snap Ring
9. Install 1-2 synchronizer hub (1) and hub snap ring (2).
Fig. 91: Synchronizer Detent & Spring

10. Install 1-2 synchronizer sleeve (3) on the hub (2) and push sleeve to the bottom of the hub.
NOTE: 1-2 synchronizer sleeve (3) and hub (2) have one small tooth. They must
be aligned to install synchronizer sleeve (3) on hub (2).
11. Install 1-2 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind
synchronizer sleeve (3).
Fig. 92: Installing First Gear Blocker Ring

12. Install first gear blocker ring (1) on synchronizer hub (2).
Fig. 93: Installing First Gear Outer Friction Ring

13. Install first gear outer friction ring (1) on synchronizer hub (2).
Fig. 94: Installing First Gear Inner Friction Ring
14. Install first gear inner friction ring (1) on synchronizer hub (2).
Fig. 95: Installing First Gear Stop Ring

15. Install first gear stop ring (1) with teeth pointing down on synchronizer rings and hub (2).
16. Hold first gear stop ring (1) on synchronizer rings (2) and center 1-2 synchronizer sleeve on the hub.
Fig. 96: First Gear & Bearing
17. Install first gear (1) and bearing (2).
Fig. 97: Heating Thrust Washer & Reverse Gear Bearing Race
18. Heat thrust washer (1) and reverse gear bearing race (2) on bearing heater to a maximum of 150 Celsius
(300° Fahrenheit).
Fig. 98: Reverse Bearing Race & Thrust Washer
19. Using welding gloves or tongs, install thrust washer (2) and reverse gear bearing race (1) on mainshaft.
Fig. 99: Reverse Gear & Bearing

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

Fig. 100: Installing Reverse Inner Blocker Ring
21. Install reverse gear inner friction ring (1) on reverse gear (2).
Fig. 101: Installing Reverse Gear Outer Friction Ring

22. Install reverse gear outer friction ring (1) on inner blocker ring (2).
Fig. 102: Installing Reverse Gear Outer Blocker Ring
23. Install reverse gear blocker ring (1) on friction ring (2).
Fig. 103: Installing Reverse Gear Synchronizer Hub & Snap Ring
24. Install reverse gear synchronizer hub (1) with snap ring (2) on the top on mainshaft.
25. Heat mainshaft bearing (1) on bearing heater (2) to a maximum of 150 Celsius (300° Fahrenheit).
Fig. 105: Installing Mainshaft Bearing On Mainshaft

26. Using welding gloves or tongs, install mainshaft (1) bearing (2) on mainshaft.
27. On 4x4 transmission install mainshaft (1) bearing (2) snap ring.
Fig. 106: Reverse Gear Synchronizer Hub & Detents
28. Install reverse synchronizer hub (1) detents (2).
Fig. 107: Reverse Gear & Synchronizer Sleeve

29. Install reverse gear (2) synchronizer sleeve (1) on hub and center sleeve on hub.
Fig. 108: Installing Third Gear Bearing On Mainshaft
30. Turn mainshaft and Fixture (special tool #9605, Fixture) over and secure in vise.
31. Install third gear bearing (1) on mainshaft (2).
Fig. 109: Installing Third Gear On Mainshaft

32. Install third gear (1) on mainshaft (2).

Fig. 110: Installing Third Gear Stop Ring
33. Install third gear stop ring (1) with teeth pointing up on third gear (2).
Fig. 111: 3rd Gear Inner Friction Ring

34. Install third gear inner friction ring (1) on stop ring (2).
Fig. 112: 3rd Gear Outer Friction Ring
35. Install third gear outer friction ring (1) on stop ring (2).
Fig. 113: 3rd Gear Blocker Ring

36. Install third gear blocker ring (1) on stop ring (2).
Fig. 114: Installing 3-4 Synchronizer Hub & Third Gear Synchronizer Rings
37. Install 3-4 synchronizer hub (1) on third gear synchronizer rings (2).

38. Install third gear synchronizer hub (1) snap ring (2).
39. Install 3-4 synchronizer sleeve (3) on hub (2) and push sleeve to the bottom of the hub.
NOTE: 3-4 synchronizer sleeve (3) and hub (2) have one small tooth. They must
be aligned to install synchronizer sleeve (3).
40. Install 3-4 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents (1)
behind synchronizer sleeve (3).
Fig. 117: Installing Fourth Gear Outer Blocker Ring

41. Install fourth gear blocker ring (1) on synchronizer hub (2).
Fig. 118: 4th Outer Friction Ring

42. Install fourth gear outer friction ring (1) on synchronizer hub (2).
Fig. 119: Installing Fourth Gear Inner Friction Ring

43. Install fourth gear inner friction ring (1) on synchronizer hub (2).
Fig. 120: Installing Fourth Gear Stop Ring
44. Install fourth gear stop ring (1) with teeth pointing down on synchronizer hub (2).
45. Hold fourth gear stop ring (1) on synchronizer hub (2) and center 3-4 synchronizer sleeve on hub.
Fig. 121: Fourth Gear & Bearing

46. Install fourth gear (1) and bearing (2).

Fig. 122: Heating Fourth Gear Thrust Washer
47. Heat fourth gear thrust washer (1) on bearing heater (2) to a maximum of 150 Celsius (300° Fahrenheit).
Fig. 123: Installing Fourth Gear Thrust Washer

48. Using welding gloves or tongs, install fourth gear (1) thrust washer (2).
Fig. 124: Fourth Gear Snap Ring
49. Install fourth gear (1) snap ring (2).
Fig. 125: Sixth Gear & Bearing

50. Install sixth gear (1) and bearing (2) on mainshaft (3).
Fig. 126: Installing Sixth Gear Stop Ring
51. Install sixth gear stop ring (1) on sixth gear (2).
Fig. 127: Installing Sixth Gear Friction Ring

52. Install sixth gear friction ring (1) on stop ring (2).
Fig. 128: Installing 5-6 Synchronizer Hub
53. Install 5-6 synchronizer hub (1) on sixth gear synchronizer rings (2).

54. Heat mainshaft bearing (1) on bearing heater to a maximum of 150 Celsius (300° Fahrenheit).
Fig. 130: Mainshaft Bearing Snap Ring
55. Using welding gloves or tongs, install mainshaft bearing (1) on mainshaft.
56. Install mainshaft bearing (1) snap ring (2).
Fig. 131: 5-6 Synchronizer Sleeve

57. Install 5-6 synchronizer sleeve (1) on hub (2) and push sleeve to the bottom of the hub.
58. Install 5-6 synchronizer detents and springs (1) into synchronizer hub (2) slots. Then push detents behind
synchronizer sleeve (3).
Fig. 133: Installing Fifth Gear Friction Ring

59. Install fifth gear friction ring (1) onto hub (2).
Fig. 134: Installing Fifth Gear Blocker Ring
60. Install fifth gear blocker ring with teeth pointing down (1) onto hub (2).
61. Hold fifth gear blocker ring (1) onto hub (2) and center 5-6 synchronizer sleeve on hub (2).
REAR HOUSING
Fig. 135: Installing Countershaft Cup

1. Install countershaft bearing cup with Installer (special tool #9589, Installer, Bearing Cup) (1) and Handle
(special tool #C-4171, Driver Handle, Universal) (2).
Fig. 136: Installing Mainshaft Cup
2. Install mainshaft bearing cup with Installer (special tool #9588, Installer, Bearing Cup) (1) and Handle
3. Install output shaft seal with Installer (special tool #9598, Installer, Seal).
Fig. 137: Installing Reverse Idler Bearing Into Idler Gear

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

Fig. 138: Reverse Idle Gear
5. Install idler gear (1) with taller thrust face up into rear housing (2) and off to the side. For
mainshaft/countershaft installation clearance.
Fig. 139: Identifying Strap & Shift Rails

6. Tie strap (2) shift rails (1) together.

Fig. 140: Identifying Shift Forks
7. Install reverse (1), 1-2 (2) and 3-4 (3) shift rails and forks as and assembly on synchronizer sleeves.
Fig. 141: Countershaft, Mainshaft & Shift Rails

8. Install mainshaft with shift rails (2) into the rear housing. Tilt the mainshaft then tilt the countershaft (1)
into the housing.
Fig. 142: Identifying Oil Slinger & Mainshaft Gears
9. Position first/reverse oil slinger (1) between the mainshaft first (2) and reverse gears, then straighten the
shafts in the housing.
CAUTION: Oil slinger is fragile and can crack during installation. Failure to
follow these instructions will result in cracking the oil slinger and
lack of oil to first/reverse bearing.
NOTE: The transmission may or not be equipped with the oil slinger. Service
replacement parts will come with an oil slinger. It is not necessary to
remove the oil slinger if the original part was not equipped with an oil
slinger.
Fig. 143: Reverse Idler Shaft
10. Position reverse idler gear and install idler shaft (2) with bolt (1).
Fig. 144: Reverse Idler Shaft Pin

11. Install reverse idler gear shaft bolt (1) into rear housing (2) and tighten to 58 N.m (43 ft. lbs.).
Fig. 145: Installing 5-6 Shift Fork Shoe Narrow Ends
12. Install 5-6 shift shoe narrow ends (1) into the 5-6 synchronizer sleeves (2).
Fig. 146: 5-6 Shift Fork

13. Install 5-6 shift fork (1) into the shift rail.
FRONT HOUSING
Fig. 147: Installing Input Shaft Seal Front Housing Bore
CAUTION: If mainshaft/bearings or countershaft/bearings are replaced, end-play

measurements must taken to ensure proper bearing preload. Failure to
follow these instructions will result in bearing damage.
1. Install input shaft seal front housing bore (1) with Installer (special tool #9595, Installer, Seal) (2).
Fig. 148: Input Shaft Seal Retainer & Bolts

2. Install input shaft retainer (1) and tighten bolts (2) to 23 N.m (17 ft. lbs.).
Fig. 149: Installing Countershaft Bearing Cup
3. Install select end play shims into the countershaft bearing cup bore.
4. Install countershaft bearing cup with Installer (special tool #9589, Installer, Bearing Cup) (1) and Handle
Fig. 150: Installing Mainshaft Bearing Cup

5. Install input shaft bearing oil supply washer and select end play shims into mainshaft bearing cup bore.
6. Install mainshaft bearing cup with Installer (special tool #9588, Installer, Bearing Cup) (1) and Handle
Fig. 151: Front & Rear Housing
7. Apply Mopar™ Gasket Maker to the rear housing sealing surface.

8. Install front housing (1) onto the rear housing (2).
9. Install housing bolts and tighten to 58 N.m (43 ft. lbs.).
Fig. 152: 5-6 Shift Fork Pivot Pin

10. Install 5-6 shift fork pin bolts (1) into housing and tighten to 58 N.m (43 ft. lbs.).
Fig. 153: Aligning Shift Rails In Neutral Position
11. Remove shift rail (2) tie strap.
Fig. 154: Flange

12. On a 4x2 transmission shift two shift rails to lock the transmission in two gears. Then install flange (1) on
output shaft (2) and tighten bolt to 260 N.m (190 ft. lbs.). Return shift rails to neutral position.
Fig. 155: Shifter Boot & Shift Tower
13. Push shift tower boot (1) onto shift tower (2).
Fig. 156: Shift Tower & Bolts

14. Apply Mopar™ Gasket Maker to the shift tower opening.

15. Install shift tower (2) and tighten bolts (1) to 23 N.m (17 ft. lbs.).
Fig. 157: Back-Up Lamp Switch
16. Install back up lamp switch (1) and bolt (2).
INSTALLATION
INSTALLATION
Fig. 158: Identifying Lubrication Points

CAUTION: The release fork is not symmetrical and must be installed with the slots
and part number stamping toward the ball stud side. Part number
stamping will be right side up when installed correctly. Failure to install
the release fork correctly will result in clutch slippage and damage.
1. Clean transmission front housing mounting surface.
2. Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of following
components:
 Release fork (1) ball stud (2)
 Release bearing slide surface (3)
 Input shaft splines (4)
 Release bearing bore (5)
 Propeller shaft slip yoke.
Fig. 159: Transmission Bolts

3. Support and secure transmission to jack.

4. Raise and align transmission input shaft with clutch disc, then slide transmission into place.
5. Install exhaust bracket diesel engine.
6. Verify front housing is fully seated.
 Diesel Engine: Install transmission bolts (1, 2) and tighten to 41 N.m (30 ft. lbs.). Tighten the bolts
with washers (2) into the transmission to 68 N.m (50 ft. lbs.).
Fig. 160: Crossmember & Bolts
7. Install crossmember and tighten nuts (2) to 102 N.m (75 ft. lbs.).
8. Install transmission mount bolts (1) and tighten to 68 N.m (50 ft. lbs.).
Fig. 161: Slave Cylinder & Mounting Nuts

9. Connect transmission harnesses to clips on case and connect switches.

10. Install slave cylinder and tighten cylinder nuts to 23 N.m (200 in. lbs.).
11. Install transfer case and transfer case linkage 4x4 equipped.
12. Remove transmission jack.
Fig. 162: Marking Manual Transmission Flange & Propeller Shaft Flange
13. Install propeller shaft/shafts with reference marks aligned.
Fig. 163: Exhaust Bracket

14. Install exhaust pipe. Refer to PIPE, EXHAUST, INSTALLATION .

15. Install exhaust bracket (1) and bolts.
Fig. 164: Fill Plug
16. Remove fill plug (1) on transmission (2) and fill to approximately 16 mm (0.625 inch) from the bottom of
the fill hole.
17. Install fill plug and tighten to 57 N.m (42 ft. lbs.).
18. Connect battery negative cable.
19. Install shift lever extension on shift tower and lever assembly.
20. Slide boot down on shift lever extension and install shift boot bezel and screws.
21. Install skid plate, if equipped.
SPECIAL TOOLS
SPECIAL TOOLS
6444 - Puller, Bearing/Gear

(Originally Shipped In Kit Number(s) 6440, 8847, 8854CC.)
6444-1 - Puller, Base
6444-3 - Rod, Long
6444-8 - Sleeve
8513A - Insert, Crankshaft
(Originally Shipped In Kit Number(s) 8283, 8527, 8575, 8999, 8999CC.)
8915 - Brace
(Originally Shipped In Kit Number(s) 8998, 8998CC, 9763.)
938 - Bridge
(Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9202, 9202A-CAN, 9202CC, 9299.)
9588 - Installer, Bearing Cup
(Originally Shipped In Kit Number(s) 9692.)
9589 - Installer, Bearing Cup
9592 - Fixture, End Play
9593 - Remover, Bearing Cup
9594 - Remover, Gear & Synchro
9595 - Installer, Seal
9597 - Remover, Bearing
9598 - Installer, Seal
9605 - Fixture
9646 - Puller, Gear
(Originally Shipped In Kit Number(s) 9526, 9575, 9692.)
9647 - Puller
(Originally Shipped In Kit Number(s) 9526, 9575, 9692.)
C-293-47 - Block Set, Puller
(Originally Shipped In Kit Number(s) 9975, C-293-M, DD-914-CLT-L.)
C-293-PA - Puller, Press
(Originally Shipped In Kit Number(s) 8418, 8837, C-293-M.)
C-4171 - Driver Handle, Universal
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)

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2012 MANUAL TRANSMISSION

G56 - Service Information - Ram Pickup

DIAGNOSIS AND TESTING

LOW LUBRICANT LEVEL

1. Raise and support vehicle.

Fig. 2: Fill Plug

4. Remove fill plug (1) on right side of the transmission (2).

CAUTION: This procedure must be performed any time a mainshaft, countershaft or

Fig. 3: Identifying Mainshaft Case Measurement

6. Place mainshaft shaft bearing cup on mainshaft bearing.

Fig. 5: Measuring Gap Between Fixture Shaft & Fixture Plunger

Fig. 6: Countershaft Case Measurement

5. Place countershaft bearing cup on countershaft bearing.

Fig. 8: Measuring Gap Between Fixture Shaft & Fixture Plunger

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Fig. 9: Identifying Inner Boot, Shift Tower & Transmission

1. With vehicle in neutral, position vehicle on hoist.

6. Remove skid plate, if equipped.

Fig. 12: Slave Cylinder & Mounting Nuts

9. Disconnect harness from clips on transmission housing.

Fig. 13: Exhaust Bracket

Fig. 14: Securing Transmission To Transmission Jack

Fig. 15: Transmission Mount Nuts

Fig. 16: Crossmember & Bolts

1. Set transmission on rear housing.

Fig. 18: Shifter Boot

Fig. 19: Flange Bolt

Fig. 20: Aligning Shift Rails In Neutral Position

Fig. 21: 5-6 Shift Fork Pivot Pin

Fig. 23: Back-Up Lamp Switch

9. Remove transmission housing bolts.

Fig. 25: 5-6 Shift Fork

12. Remove input shaft (1) from mainshaft (2).

Fig. 27: Reverse Idler Shaft

Fig. 29: Countershaft, Mainshaft & Shift Rails

Fig. 31: Identifying Shift Forks

Fig. 33: 5-6 Synchronizer Springs

5. Remove 5-6 synchronizer sleeve (1) from hub (2).

Fig. 35: Mainshaft Bearing Snap Ring

6. Remove mainshaft bearing (1) snap ring (2).

Fig. 37: Sixth Gear & Bearing

9. Remove fourth gear (1) snap ring (2).

Fig. 41: Fourth Gear & Bearing

12. Remove fourth gear (1) and bearing (2).

Fig. 43: 3-4 Synchronizer Sleeve & Springs

16. Remove 3-4 synchronizer hub (1) snap ring (2).

18. Remove third gear (1) and bearing (2).

Fig. 47: Reverse Gear & Synchronizer Sleeve

22. Remove reverse gear synchronizer hub (1) detents (2).

Fig. 49: Removing Mainshaft Bearing

Fig. 51: Reverse Gear & Bearing

25. Remove reverse gear (1) and bearing (2).

Fig. 53: First Gear & Bearing

27. Remove first gear (1) and bearing (2).

Fig. 55: 1-2 Synchronizer Sleeve & Springs

Fig. 57: 2nd Gear

31. Remove second gear (1) from mainshaft (2).

32. Remove second gear bearing (1) from mainshaft (2).

Fig. 59: Removing Countershaft Rear Bearing