Dodge Journey: Assembly

Manual Transmission BG6
Fig. 65: Remove Input Shaft Bearing Cup

NOTE: Always use ATF on all moving parts during this assembly procedure.

1. Use Bearing Cup Remover 9664 (2) and appropriate Slide Hammer (1) to remove the output shaft #2 tapered bearing cup (3) from the transmission rear case.

Manual Transmission BG6
Fig. 66: Compounder Shaft Bearing Cup Shim

2. Remove the output shaft #2 bearing cup shim (1) from the transmission rear case (2).

NOTE: A turning torque will determine the correct shim to be installed. This can be found at the end of the assembly procedure.

3. Install the correct output shaft #2 bearing cup shim into the transmission case.

Manual Transmission BG6
Fig. 67: Installing Output Shaft #2 Bearing Cup

4. Install the output shaft #2 bearing cup (3) into the transmission rear case using Handle C-4171 and Seal/Cup Installer L-4520.

Manual Transmission BG6
Fig. 68: Bearing Cup Remover & Output Shaft #2 Bearing Cup

5. Remove the output shaft #2 bearing cup (3) using Bearing Cup Remover 9664 (2) and appropriate slide hammer (1).

Manual Transmission BG6
Fig. 69: Input Shaft Oil Slinger

6. Remove the oil slinger (1) under the output shaft # 2 cup on the bellhousing side.

7. Install the oil slinger (1) in the case (2) for the compounder shaft bearing cup on the bellhousing side, insure the tab (3) is lined up with cutout in case (2).

Manual Transmission BG6
Fig. 70: Compounder Shaft Bearing Cup

8. Use Handle C-4171 and Bearing Cup Installer D-144, inverted to install the compounder shaft cup on the bellhousing side case.

Manual Transmission BG6
Fig. 71: Input Shaft Case Bearing & Bearing Cup Remover

9. Remove the input shaft case bearing (3) (bellhousing side) using Bearing Cup Remover 7794-A (1) and appropriate slide hammer.

Manual Transmission BG6
Fig. 72: Remove Input Shaft Seal

10. Using a screwdriver (1) remove the input shaft seal (2).

Manual Transmission BG6
Fig. 73: Install Input Shaft Oil Seal

11. Using handle C-4171 and Installer 9935 (2) install the new input shaft oil seal.

Manual Transmission BG6
Fig. 74: Install Input Shaft Case Bearing

12. Install the input shaft case bearing (2) using Handle C-4171 (1) and Bearing Installer C-4657 (2).

Manual Transmission BG6
Fig. 75: Remove Output Shaft Bearing From Case

13. Using Bearing Cup Remover 7794-A (2) and appropriate slide hammer (1) remove the output shaft #1 bearing (3) from the case (1).

Manual Transmission BG6
Fig. 76: Output Shaft Oil Slinger

14. Remove the output shaft oil slinger (2) from case.

15. Install the output shaft oil slinger (2) into the case , insure the tab (3) is lined up with cutout in case (2).

Manual Transmission BG6
Fig. 77: Install Output Bearing To Case

16. Using Handle C-4171 (1) and Bearing Installer C- 4308 inverted (2) install output bearing (3) to case (4).

Manual Transmission BG6
Fig. 78: Handle & Bearing Cup Installer

17. Remove the case side differential bearing cup using Handle C-4171 (1) and Bearing Cup Installer 9589 (2), inverted.

Manual Transmission BG6
Fig. 79: Differential Bearing Cup Shim

18. Remove the case side differential bearing cup shim (1).

NOTE: The case side differential bearing cup shim (1) will be left out to find end play then installed to check turning torque later in the assembly procedure. DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

19. Install the correct case side differential bearing cup shim (1).

Manual Transmission BG6
Fig. 80: Install Differential Bearing Cup

20. Install the case side differential bearing cup (3) using Handle C-4171 (1) and Bearing Cup Installer D-111 (2).

Manual Transmission BG6
Fig. 81: Bell Housing Side Differential Bearing Cup

21. Install the bellhousing side differential bearing cup (3) using Handle C-4171 (1) and Bearing Cup Installer D-111 (2) on FWD transmissions and Bearing Cup Installer 8151 (2) on AWD transmissions.

Manual Transmission BG6
Fig. 82: Oil Baffle

22. Install oil baffle (2) and bolts (1), tighten bolts to 9 N.m (80 in. lbs.).

Manual Transmission BG6
Fig. 83: Oil Feed Trough

23. Install the oil feed trough (1) into the case (2).

Manual Transmission BG6
Fig. 84: Magnet

24. Install the magnet (1) into the case.

Manual Transmission BG6
Fig. 85: Differential

25. Install the differential (1) into the case (5).

26. Verify differential bearing preload and turning torque.

Manual Transmission BG6
Fig. 86: Output & Input Shafts

27. Install the output # 1 (1) and input shaft (2) into case together.

Manual Transmission BG6
Fig. 87: Bolt At Output Shaft

28. Install the output shaft (2) hold down bolt (4) and tighten to 11 N.m (97 in. lbs.).

Manual Transmission BG6
Fig. 88: Reverse Idler Gear

29. Install the reverse idler gear assembly (1) into the case (2).

Manual Transmission BG6
Fig. 89: Output Shaft #2

30. Install the output shaft # 2 (4) into case.

Manual Transmission BG6
Fig. 90: Oil Slinger

31. Install the oil slinger (1) and bolts (2) tighten the bolts to 9 N.m (80 in. lbs.).

Manual Transmission BG6
Fig. 91: Bolt At Reverse Idler Gear

NOTE: Clock the reverse idler (1) with hole as shown in illustration for installation of anti-rotation bolt.

32. Install the reverse idler gear (1) hold down bolt (2) and tighten to 11 N.m (97 in. lbs.).

Manual Transmission BG6
Fig. 92: First & Second Gear Shift Fork & Synchronizer

33. Install the first and second gear shift fork (1) onto the first and second gear synchronizer (2).

Manual Transmission BG6
Fig. 93: Third & Fourth Gear Shift Fork & Synchronizer

34. Install the third and fourth gear shift fork (1) onto the third and fourth gear synchronizer.

Manual Transmission BG6
Fig. 94: Shift Rail Pivot Bracket

35. Install the shift rail arm (1) onto the stand (2).

Manual Transmission BG6
Fig. 95: Pivot Shaft

36. Install the pivot shaft (1) into the case.

Manual Transmission BG6
Fig. 96: Shift Rail Pin

37. Install the shift rail bracket pivot pin (1) and the new pivot pin E-clip (2).

Manual Transmission BG6
Fig. 97: Third & Fourth Gear Shift Bracket

38. Install the third and fourth gear shift bracket (1).

Manual Transmission BG6
Fig. 98: Third & Fourth Gear Shift Rail

39. Install the third and fourth gear shift rail (1) into the case and shift fork (4).

Manual Transmission BG6
Fig. 99: Roll Pin At Third & Fourth Gear Shift Rail

40. Install the new roll pin at the third and fourth gear shift rail.

Manual Transmission BG6
Fig. 100: First & Second Gear Shift Rail

41. Install the first and second gear shift rail (1).

Manual Transmission BG6
Fig. 101: Roll Pin At Third & Fourth Gear Shift Fork To Rail

42. Install the new roll pin at the third and fourth gear shift fork to rail (1).

Manual Transmission BG6
Fig. 102: First & Second Gear Shift Fork To Rail Bolt

43. Install the new bolt (2) holding the first and second gear shift fork (3) to the rail and tighten to 20 N.m (177 in. lbs.).

Manual Transmission BG6
Fig. 103: Fifth & Sixth Gear Shift Fork

44. Install the fifth and sixth gear shift fork (2).

Manual Transmission BG6
Fig. 104: Reverse Gear Shift Fork

45. Install the reverse gear shift fork (1).

Manual Transmission BG6
Fig. 105: Fifth & Sixth Gear Shift Rail

46. Install the fifth and sixth gear shift rail (1) into the case and shift fork (2).

Manual Transmission BG6
Fig. 106: Fifth & Sixth Gear Shift Fork & Shift Rail Bolt

47. Install the new bolt (2) holding the fifth and sixth gear shift fork (3) to the fifth and sixth gear shift rail (1) and tighten to 20 N.m (177 in. lbs.).

Manual Transmission BG6
Fig. 107: Reverse Shift Rail

48. Install the reverse shift rail (1) into the case (3) and shift fork (2).

Manual Transmission BG6
Fig. 108: Reverse Shift Fork To Shift Rail Bolt

49. Install the new bolt (1) holding the reverse shift fork (5) to the reverse shift rail (6) and tighten to 20 N.m (177 in. lbs.).

Manual Transmission BG6
Fig. 109: Third & Fourth Gear Shift Rail Detent Spacer & Spring

50. Install third and fourth gear shift rail detent ball.

51. Install third and fourth gear shift rail detent spacer (3) and spring (2).

Manual Transmission BG6
Fig. 110: Third & Fourth Gear Shift Rail Detent Plug

52. Install a new third and fourth gear shift rail detent plug (1) and tighten to 22 N.m (195 in. lbs.).

Manual Transmission BG6
Fig. 111: First & Second Gear Shift Rail Detent Spacer & Spring

53. Install first and second gear shift rail detent ball.

54. Install first and second gear shift rail detent spacer and spring.

55. Install a new first and second gear shift rail detent plug (1) and tighten to 22 N.m (195 in. lbs.).

Manual Transmission BG6
Fig. 112: Reverse Shift Rail Detent Ball

56. Install the reverse shift rail detent ball (2).

Manual Transmission BG6
Fig. 113: Reverse Shift Rail Detent Spacer & Spring

57. Install the reverse shift rail detent spacer (3) and spring (2).

Manual Transmission BG6
Fig. 114: Reverse Shift Rail Detent Plug

58. Install a new reverse shift rail detent plug (1) and tighten to 22 N.m (195 in. lbs.).

Manual Transmission BG6
Fig. 115: Fifth & Sixth Gear Shift Rail Detent Ball

59. Install fifth and sixth gear shift rail detent ball (2).

Manual Transmission BG6
Fig. 116: Fifth & Sixth Gear Shift Rail Detent Spacer & Spring

60. Install fifth and sixth gear shift rail detent spacer (3) and spring (2).

Manual Transmission BG6
Fig. 117: Fifth & Sixth Gear Shift Rail Detent Plug

61. Install a new fifth and sixth gear shift rail detent plug (1) and tighten to 22 N.m (195 in. lbs.).

Manual Transmission BG6
Fig. 118: Flat Surface Of Case Mating Flange

62. If this is the final assembly draw a bead (1) of MOPAR Gasket Maker, Loctite 518, or equivalent, on the flat surface of the case mating flange (2).

Manual Transmission BG6
Fig. 119: Transmission Case Half & Clutch Housing

63. Install the transmission case half (1) onto the clutch housing (2).

Manual Transmission BG6
Fig. 120: Snap Rings At Rear Of Transmission Case

CAUTION: Insure snap rings are fully seated in bearings before installing case bolts.

64. Using suitable snap-ring pliers (3), expand the transmission shaft bearing snap-rings (1, 2) at the rear of the transmission case to allow the bearings fall into place.

Manual Transmission BG6
Fig. 121: 27 MM Hex Adapter For Shaft Plug

NOTE: Always use a new washer anti-rotation bolt.

NOTE: Add MOPAR Gasket Maker, Loctite 518, or equivalent around inside flat of plug.

65. Install the new 27 mm the shaft plug (2) into the rear of the case.

66. Install a 27 mm (1 1/16 in.) hex adapter (1) into the shaft plug (2) at the rear of the transmission case (3) and tighten to 55 N.m (41 ft. lbs.).

Manual Transmission BG6
Fig. 122: Idler Shaft Anti-Rotation Bolt

NOTE: Always use a new washer anti-rotation bolt.

NOTE: Next step only to be used on final assembly.

67. Install anti-rotation bolt (2) and washer (3) tighten to 80 N.m (59 ft. lbs.).

Manual Transmission BG6
Fig. 123: Transmission Case To Clutch Housing Bolts (Transmission Case Side)

68. Install the bolts (1) holding the transmission case (2) to the clutch housing (3) on the transmission case side and tighten to 29 N.m (257 in. lbs.).

Manual Transmission BG6
Fig. 124: Transmission Case To Clutch Housing Bolts (Inside Clutch Housing)

69. Install the bolts (1) holding the transmission case to the clutch housing on the inside of the clutch housing and tighten to 29 N.m (257 in. lbs.).

Manual Transmission BG6
Fig. 125: Sealer

70. Add MOPAR Gasket Maker, Loctite 518, or equivalent around inside of all holes and on mating flange.

Manual Transmission BG6
Fig. 126: Shift Lever Assembly

71. Install the shift lever assembly (1) into the transmission case (2).

Manual Transmission BG6
Fig. 127: Shift Lever Assembly Bolts

72. Install the new bolts (1) holding the shift lever assembly (2) to the transmission and tighten to 19 N.m (168 in. lbs.)

Manual Transmission BG6
Fig. 128: Anti-Rotation Bolt

73. Install new shift tower lock ball for shift detent (5) and tighten to 29 N.m (277 in. lbs.).

74. Install new shift lock ball for the select detent (3) and tighten to 39 N.m (29 ft. lbs.).

75. Install new shift tower shift guide pin (2) and tighten to 30 N.m (257 in. lbs.).

Manual Transmission BG6
Fig. 129: Crossover Bracket

76. Install the shift bracket (2) and bolts, tighten to 19 N.m (168 in. lbs.)

Manual Transmission BG6
Fig. 130: Crossover Bellcrank

77. Install the crossover (1) onto the transmission.

78. Install the crossover bolts (1) and tighten to 19 N.m (168 in. lbs.)

Manual Transmission BG6
Fig. 131: Bell Crank Bushing

79. Apply a light coating of white grease on crossover bushing (1).

80. Install the crossover bushing (1) onto the crossover shaft (2).

Manual Transmission BG6
Fig. 132: Nut Crossover Rod To Shift Lever

81. Install 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 tighten to 12 N.m (106 in. lbs.).

Manual Transmission BG6
Fig. 133: Shift Cable Bracket

CAUTION: Be sure to verify bracket position after installation.

82. Install the shift cable bracket (1) to the transmission case.

83. Install the bolts (2) holding the shift cable bracket (1) to the transmission case and tighten to 19 N.m (168 in. lbs.).

Manual Transmission BG6
Fig. 134: Back-Up Lamp Switch

84. Install the backup lamp switch (1) with a new washer and tighten to 40 N.m (29 ft. lbs.).

Manual Transmission BG6
Fig. 135: Drain Plug

85. Install the drain plug (1) with a new gasket and tighten to 39 N.m (29 ft. lbs.).

BEARING ADJUSTMENT PROCEDURE

1. Use extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat gives a false end-play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to low mileage failures.

2. Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.

3. Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures.

Used (original) bearings may lose up to 50% of the original drag torque after break-in. All bearing adjustments must be made with no other component interference or gear intermesh.

4. Replace bearings as a pair: If one differential bearing is defective, replace both differential bearings, if one input shaft bearing is defective, replace both input shaft bearings.

5. Bearing cones must not be reused if removed.

6. Turning torque readings should be obtained while smoothly rotating in either direction.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

NOTE: True bearing turning torque readings can be obtained only with the geartrain removed from the case.

1. Remove bearing cup and existing shim from clutch bellhousing case.

2. Press in new bearing cup into bellhousing case (or use a cup that has been ground down on the outer edge for ease of measurement).

3. Press in new bearing cup into gear case side.

4. Oil differential bearings with transmission fluid. Install differential assembly in transaxle gear case.

Install clutch bellhousing over gear case. Install and tighten case bolts to 29 N.m (257 in. lbs.).

5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.

NOTE: The dial indicator should be parallel to T-Handle to obtain the most accurate reading.

6. Apply a medium load to differential with Torque Tool C-4995A (3) and a T-handle, in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator (2). To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth. Record end play.

7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18 mm (0.007 in.). Never combine shims to obtain the required preload.

8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected, then press the bearing cup into clutch bellhousing.

9. Install clutch bellhousing. Install and tighten case bolts to 29 N.m (257 in. lbs.).

10. Using Torque Tool C-4995A (2) and an inch-pound torque wrench (1), check turning torque of the differential assembly. The turning torque should be 1 to 3 N.m (9 to 22 in. lbs.) If the turning torque is too high, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thicker shim.

11. Recheck turning torque (1). Repeat until the proper turning torque is obtained.

12. Once proper turning torque has been established for the differential separate case halves, install output shaft # 2 assembly into case with the differential and recheck differential turning torque. The turning torque should be 4 to 6 N.m (37 to 52 in. lbs.) If the turning torque is too high, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thicker shim.

13. Recheck total turning torque (1). Repeat until the proper turning torque is obtained.

Once proper turning torque has been established, place gear case on the end plate. Draw a bead of MOPAR Gasket Maker, Loctite 518, or equivalent, on the flat surface of the case mating flange.

Install clutch bellhousing onto gear case. Install and tighten case bolts to 29 N.m (257 in. lbs.).

14. Install axle seal (case side) on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore.

15. Tap seal into position until seated against transaxle case.

Manual Transmission BG6
Fig. 136: Aligning Axle Shaft Seal With Axle Shaft Seal Bore

16. Install axle seal (bellhousing side) on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore.

17. Tap seal into position until seated against transaxle case.

    Disassembly
    Fig. 10: Drain Plug 1. Remove drain plug (1) and allow transmission oil to drain. Fig. 11: Back-Up Lamp Switch 2. Remove backup lamp switch (1). Fig. 12: Shift Cable Bracket 3. Remove the b ...

    Installation
    Fig. 137: Rear Mount Bracket 1. If transmission brackets were removed or transmission was replaced install the rear mount bracket and tighten (1) to 100 N.m (74 ft. lbs.). Fig. 138: Front Mou ...

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