Dodge Journey: Disassembly

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Fig. 10: Drain Plug

1. Remove drain plug (1) and allow transmission oil to drain.

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Fig. 11: Back-Up Lamp Switch

2. Remove backup lamp switch (1).

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Fig. 12: Shift Cable Bracket

3. Remove the bolts (2) holding the shift cable bracket (1) to the transmission case.

4. Remove the bracket from the transmission (1).

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Fig. 13: Nut Crossover Rod To Shift Lever

5. Remove the nut (4) holding the crossover rod (2) to the shift lever. Be sure to use a wrench (1) to hold the ball stud to prevent it from rotating in the shift lever.

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Fig. 14: Crossover Bellcrank

6. Remove bolts (1) holding crossover bellcrank (2) to the transmission case.

7. Remove the crossover bellcrank from the transmission.

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Fig. 15: Bell Crank Bushing

8. Be sure to locate the bell crank bushing on the bell crank or the shift lever and set aside for installation.

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Fig. 16: Crossover Bracket

9. Remove the bolts (1) at the shift lever bracket (2).

10. Remove the shift lever bracket (2).

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Fig. 17: Anti-Rotation Bolt

11. Loosen and remove shift lock ball for the shift detent (5).

12. Loosen and remove shift lock ball for the select detent (3).

13. Loosen and remove shift guide pin (2).

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Fig. 18: Shift Lever Assembly Bolts

14. Remove the bolts holding the shift lever assembly to the transmission.

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Fig. 19: Shift Lever Assembly

15. Remove the shift lever assembly from the transmission case.

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Fig. 20: Transmission Case To Clutch Housing Bolts (Inside Clutch Housing)

16. Remove the bolts (1) holding the transmission case to the clutch housing from inside the clutch housing.

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Fig. 21: Transmission Case To Clutch Housing Bolts (Transmission Case Side)

17. Remove the bolts (1) holding the transmission case (2) to the clutch housing (3) from the transmission case side.

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Fig. 22: Axle Shaft Seal Removal

18. Insert a flat-blade pry tool (2) at outer edge of axle shaft seals (1).

19. Tap on the pry tool (2) with a small hammer and remove both (case and bell housing sides) axle shaft seals (1).

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Fig. 23: Idler Shaft Anti-Rotation Bolt

20. Remove anti-rotation bolt (2) and discard old washer a new washer will be used during assembly.

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Fig. 24: 27 MM Hex Adapter For Shaft Plug

21. Install a 27 mm (1 1/16 in.) hex adapter (1) into the shaft plug (2) at the rear of the transmission case (3).

22. Loosen and remove the shaft plug (2) in the rear of the transmission case.

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Fig. 25: Snap Rings At Rear Of Transmission Case

23. Using suitable snap-ring pliers (3), release the transmission shaft bearing snap-rings (1, 2) at the rear of the transmission case.

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Fig. 26: Transmission Case Half & Clutch Housing

24. Remove the transmission case half (1) from the clutch housing (2).

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Fig. 27: Fifth & Sixth Gear Shift Rail Detent Plug

25. Remove fifth and sixth gear shift rail detent plug (1).

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Fig. 28: Fifth & Sixth Gear Shift Rail Detent Spacer & Spring

26. Remove fifth and sixth gear shift rail detent spacer (3) and spring (2).

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Fig. 29: Fifth & Sixth Gear Shift Rail Detent Ball

27. Remove fifth and sixth gear shift rail detent ball (2).

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Fig. 30: Reverse Shift Rail Detent Plug

28. Remove reverse shift rail detent plug (1).

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Fig. 31: Reverse Shift Rail Detent Spacer & Spring

29. Remove the reverse shift rail detent spacer (3) and spring (2).

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Fig. 32: Reverse Shift Rail Detent Ball

30. Remove the reverse shift rail detent ball (2).

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Fig. 33: Third & Fourth Gear Shift Rail Detent Plug

31. Remove third and fourth gear shift rail detent plug (1).

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Fig. 34: Third & Fourth Gear Shift Rail Detent Spacer & Spring

32. Remove third and fourth gear shift rail detent spacer (3) and spring (2).

33. Remove third and fourth gear shift rail detent ball.

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Fig. 35: Third & Fourth Gear Shift Rail Detent Ball

34. Remove third and fourth gear shift rail detent ball (2).

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Fig. 36: First & Second Gear Shift Rail Detent Plug

35. Remove first and second gear shift rail detent plug (1).

36. Remove first and second gear shift rail detent spacer and spring.

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Fig. 37: First & Second Gear Shift Rail Detent Ball

37. Remove first and second gear shift rail detent ball (3).

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Fig. 38: Reverse Shift Fork To Shift Rail Bolt

38. Remove the bolt (1) holding the reverse shift fork (5) to the reverse shift rail (6).

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Fig. 39: Reverse Shift Rail

39. Remove the reverse shift rail from case and shift fork.

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Fig. 40: Fifth & Sixth Gear Shift Fork & Shift Rail Bolt

40. Remove the bolt (2) holding the fifth and sixth gear shift fork (3) to the fifth and sixth gear shift rail (1).

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Fig. 41: Fifth & Sixth Gear Shift Rail

41. Remove the fifth and sixth gear shift rail (1) from case and shift fork (2).

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Fig. 42: Reverse Gear Shift Fork

42. Remove the reverse gear shift fork (1).

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Fig. 43: Fifth & Sixth Gear Shift Fork

43. Remove the fifth and sixth gear shift fork (2).

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Fig. 44: First & Second Gear Shift Fork To Rail Bolt

44. Remove the bolt (2) holding the first and second gear shift fork (3) to the rail.

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Fig. 45: Roll Pin At Third & Fourth Gear Shift Fork To Rail

45. Using a hammer and a punch (3) remove the roll pin at the third and fourth gear shift fork to rail (1).

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Fig. 46: First & Second Gear Shift Rail

46. Remove the first and second gear shift rail (1).

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Fig. 47: Roll Pin At Third & Fourth Gear Shift Rail

47. Using a hammer and a punch (3) remove the roll pin at the third and fourth gear shift rail.

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Fig. 48: Third & Fourth Gear Shift Rail

48. Remove the third and fourth gear shift rail (1) from case and shift fork (4).

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Fig. 49: Third & Fourth Gear Shift Bracket

49. Remove the third and fourth gear shift bracket (1).

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Fig. 50: Shift Rail Pin

50. Remove the E-clip and shift rail bracket pivot pin (1).

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Fig. 51: Pivot Shaft

51. Remove the pivot shaft (1) from case.

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Fig. 52: Shift Rail Pivot Bracket

52. Remove the shift rail pivot bracket (1) from the stand (2).

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Fig. 53: Third & Fourth Gear Shift Fork & Synchronizer

53. Remove the third and fourth gear shift fork (1) from synchronizer.

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Fig. 54: First & Second Gear Shift Fork & Synchronizer

54. Remove the first and second gear shift fork (1) from synchronizer (2).

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Fig. 55: Bolt At Reverse Idler Gear

55. Remove the reverse idler gear (1) hold down bolt (2).

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Fig. 56: Oil Slinger

56. Remove the bolts (2) at the oil slinger (1) and remove the oil slinger.

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Fig. 57: Output Shaft #2

57. Remove the output shaft #2 (1) from case.

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Fig. 58: Reverse Idler Gear

58. Remove the reverse idler gear (1), shaft, bearing and thrust washer from the case.

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Fig. 59: Bolt At Output Shaft

59. Remove the output shaft (2) hold down bolt (4) from the case.

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Fig. 60: Output & Input Shafts

60. Remove the output (1) and input (2) from case together.

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Fig. 61: Differential

61. Remove the differential (1) from the case (5).

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Fig. 62: Magnet

62. Remove the magnet (1) from the case.

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Fig. 63: Oil Feed Trough

63. Remove the oil feed trough (1) from the case.

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Fig. 64: Oil Baffle

64. Remove the bolts (1) holding the oil baffle.

65. Remove the oil baffle (2).

CLEANING

Clean the gears, bearings, shafts, synchronizers, thrust washers, oil feeder, shift mechanism, gear case, and bellhousing. Do not use solvent to clean sealed bearings. Dry all parts except the bearings with compressed air.

Allow the bearings to either air dry or wipe them dry with clean shop towels.

INSPECTION

Inspect the gears, bearings and shafts. Replace the bearings and cups if the rollers are worn, chipped, cracked, flat spotted, brinnelled, or if the bearing cage is damaged or distorted. Replace the gears if the teeth are chipped, cracked or worn thin. Inspect the synchronizers. Replace the sleeve if worn or damaged in any way. Replace the stop rings if the friction material is burned, flaking off, or worn. Check the condition of the synchro keys and springs. Replace these parts if worn, cracked, or distorted.

    Removal
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    Assembly
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