Dodge Journey: Assembly

Manual Transmission BG6
Fig. 214: First Gear Needle Bearing & Output Shaft

NOTE: Use ATF on all parts that are to be assembled in this procedure.

1. Install the first and first gear needle bearing (2) on the output shaft (1).

Manual Transmission BG6
Fig. 215: Synchronizer

NOTE: Pay attention to the direction when inserting the 1st-2nd hub sleeve.

2. Install the 1st-2nd synchronizer onto the output shaft with (2) towards first gear.

Manual Transmission BG6
Fig. 216: First Gear & First/Second Gear Synchronizer

3. Using a press (4), install first gear (3) and first/second gear synchronizer onto output shaft.

Manual Transmission BG6
Fig. 217: Ball

4. Install the second ball (1).

Manual Transmission BG6
Fig. 218: Output Shaft 2nd Gear

5. Install the needle bearing on the output shaft.

6. Install second gear (1) onto output shaft (2).

Manual Transmission BG6
Fig. 219: Output Shaft Spacer

7. Install the inner race (1) onto the output shaft (2).

Manual Transmission BG6
Fig. 220: Snap Ring From Output Shaft

8. Install the new C- clip (1) onto output shaft (2).

9. Install the spacer.

Manual Transmission BG6
Fig. 221: Bearing & Output Shaft

10. Install the forth bearing (1) onto the output shaft (2).

11. Install forth gear onto output shaft.

Manual Transmission BG6
Fig. 222: Synchronizer

NOTE: Pay attention to the direction when inserting the 1st-2nd hub sleeve.

12. Install the third/forth gear synchronizer onto the output shaft with (2) towards forth gear.

Manual Transmission BG6
Fig. 223: Third/Fourth Gear Synchronizer

13. Using a press install third/forth gear synchronizer (2) onto output shaft (1).

NOTE: Always use the largest snap that will fit into the grove.

14. Install a new snap ring (3) to hold third/forth gear synchronizer (2) onto output shaft (1).

Manual Transmission BG6
Fig. 224: Output Shaft Needle Bearing

15. Install the third needle bearing (1) onto output shaft (2).

Manual Transmission BG6
Fig. 225: 3rd Gear, Bearing & Press

16. Install third gear (2) onto output shaft.

17. Install the ball, spacer and bearing (3) using a Press (1).

Manual Transmission BG6
Fig. 226: Snap Ring At Output Shaft Case Bearing

NOTE: Always use the largest snap that will fit into the grove.

18. Install the new snap ring (2) from the output shaft.

Manual Transmission BG6
Fig. 227: Installing Cylindrical Roller Bearing Race

19. Using installer 6052 (2) and a Press (1) install the cylindrical roller bearing race (3) on the input shaft.

Manual Transmission BG6
Fig. 228: Input Lower Snap Ring

20. Install the shaft snap ring (2).

    Disassembly
    Fig. 200: Snap Ring At Output Shaft Case Bearing 1. Remove the snap ring (2) from the output shaft. Fig. 201: Output Shaft Case Bearing And Gear 2. Use Bearing Splitter P-334 (3), Cage 8925-3 ( ...

    See also:

    Insulator, engine mount, left
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    Actuator, recirculation door
    DESCRIPTION Fig. 15: Blend Door Actuators The recirculation door actuator (1) is a reversible, 12 volt direct current (DC) servo motor, which is connected directly to the pivot shaft lever of t ...

    Diagnosis and Testing
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