DR TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE

TABLE OF CONTENTS
page page

MANUAL TRANSMISSION - G56 - SERVICE AUTOMATIC TRANSMISSION - 48RE - DIESEL -

INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . 1105
MANUAL TRANSMISSION - GETRAG 238 - AUTOMATIC TRANSMISSION - 48RE - SERVICE
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . 69 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1266
MANUAL TRANSMISSION-T56 - SERVICE TRANSFER CASE - ELECTRICAL
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 141 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 1499
AUTOMATIC TRANSMISSION 42RLE - TRANSFER CASE - NV241 GENII - SERVICE
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 202 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1563
AUTOMATIC TRANSMISSION 42RLE - SERVICE TRANSFER CASE - NV271 - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 388 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1605
AUTOMATIC TRANSMISSION - 545RFE - TRANSFER CASE - NV243 - SERVICE
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 579 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1656
AUTOMATIC TRANSMISSION - 45RFE/545RFE - TRANSFER CASE - NV244 GENII - SERVICE
SERVICE INFORMATION . . . . . . . . . . . . . . . . . 842 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1700
AUTOMATIC TRANSMISSION - 48RE - GAS - TRANSFER CASE - NV273 - SERVICE
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . 987 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 1743

MANUAL TRANSMISSION - G56 - SERVICE INFORMATION

TABLE OF CONTENTS
page page

MANUAL TRANSMISSION - G56 - SERVICE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INFORMATION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
MANUAL TRANSMISSION - G56 . . . . . . . . . . . . . . . 2 ADJUSTMENTS
STANDARD PROCEDURE MAINSHAFT/COUNTERSHAFT BEARING
DRAIN AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PRELOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MANUAL TRANSMISSION-G56 . . . . . . . . . . . . . . . 65
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
21 - 2 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
MANUAL TRANSMISSION - G56 - SERVICE INFORMATION
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 bear-
ings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 3

STANDARD PROCEDURE
DRAIN AND FILL
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.).

4. Remove fill plug (1) on right side of the transmis-

sion (2).
5. Fill transmission even with the bottom of the fill
hole.
6. Install fill plug and tighten to 57 N·m (42 ft. lbs.).
21 - 4 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
REMOVAL
1. With vehicle in neutral, position vehicle on hoist.
2. Disconnect battery negative cable.
3. Remove shift boot bezel screws and slide boot
upward on shift lever extension.
4. Remove shift lever extension from the shift tower
and lever assembly.
5. Remove 4WD shift boot if equipped.
6. Remove skid plate, if equipped.
7. Remove drain plug (1) from transmission (2) and
drain fluid.

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.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 5

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.

13. Remove starter motor (1) on 5.7L engine.

21 - 6 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
14. Remove structural dust cover (1) clutch housing
bolts (2) and dust shield bolts (3) on 5.7L engine.

CAUTION: On 5.7L engine do not remove struc-

tural dust cover from engine block. If cover is
removed clutch housing and structural dust cover
must be aligned with the engine.

15. Remove exhaust bracket (1) bolts and remove

bracket on diesel engine.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 7

16. Support engine with adjustable jack stand and

wood block.
17. Support and secure transmission (1) to a trans-
mission jack (2) with safety chains.

18. Remove transmission mount bolts (1).

19. Remove rear crossmember bolts (2) and remove
crossmember with transmission mount.
20. Remove exhaust Y-pipe on 5.7L engine.
21. Remove bolts attaching transmission to the
engine.
22. Move transmission rearward until input shaft is
clear of clutch disc and pressure plate. Then
lower jack and remove transmission from under
vehicle.
21 - 8 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
DISASSEMBLY
1. Set transmission on rear housing.
2. Remove shift tower bolts (1) and shift tower (2).

3. Pry off shift tower boot (1) with a screw driver (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 9

4. Through the shift tower opening (1) align shift rails

(2) and install tie strap to shift rails.

5. Remove 5-6 shift fork pivot pin (1) from both sides
of the case.

6. Remove reverse idler gear shaft pin (1) from the

rear housing (2).
21 - 10 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
7. Remove back-up lamp switch (1) bolt (2) and
remove switch.

8. Remove transmission housing bolts.

9. Tap housing with dead-blow hammer and lift front
housing (1) off rear housing (2).

10. Remove 5-6 shift fork (1) from shift rail and syn-
chronizer sleeve (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 11

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

12. Thread a M6x1bolt (1) into the reverse idler gear

shaft (2) and pull shaft out of rear housing.

13. Slide reverse idler gear (1) off to the side of the
case (2) for disassembly clearance.
21 - 12 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
14. Lift and tilt countershaft (1) then remove main-
shaft with shift rails (2).
15. Remove countershaft.

16. Remove reverse idler gear (1) from rear housing

(2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 13

MAINSHAFT

1. Remove reverse (1) 1-2 (2) and 3-4 (3) shift forks
and shift rails as an assembly from mainshaft.

2. Position mainshaft in Fixture 9605 mounted in a

vise with sixth gear up.
3. Remove fifth gear synchronizer rings (1) from 5-6
synchronizer hub (2).
21 - 14 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
4. Slowly pull 5-6 synchronizer sleeve (1) up on hub
(2) enough to remove detents and springs (3).

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

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

DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 15

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).

8. Remove sixth gear (1) and bearing (2) from main-

shaft (3).

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

21 - 16 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
10. Remove fourth gear thrust washer (1) with Puller
9594. Position puller under fourth gear synchro-
nizer stop ring (2).

11. Install Bridge 938 (1) into Puller 9594 (2) and
remove fourth gear thrust washer (3).

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

DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 17

13. Remove fourth gear synchronizer rings (1) from

3-4 synchronizer hub (2) and mark installation
reference.

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.

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

21 - 18 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
17. Remove 3-4 synchronizer hub (1) and third gear
synchronizer rings (2). Mark components for
installation reference.

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

19. Turn mainshaft and Fixture 9605 and secured in

vise.
20. Remove 4x4 mainshaft snap ring.
21. Remove reverse gear synchronizer sleeve (1)
from reverse gear (2) synchronizer hub.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 19

22. Remove reverse gear synchronizer hub (1)

detents (2).

23. Remove mainshaft bearing (1) with Bridge 938 (2)

and bearing Puller 9647 (3).

24. Position puller (1) behind reverse synchronizer

hub and outer blocker ring (2).
21 - 20 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
25. Remove reverse gear (1) and bearing (2).

26. Remove reverse gear bearing race (1) and thrust

washer (2). Use Puller 9646 and Bridge 938 on
first gear (3) to pull off reverse gear bearing race
(1) and thrust washer (2).

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

DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 21

28. Remove first gear synchronizer rings (1) from 1-2

synchronizer hub (2) and mark for installation
reference.

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.
21 - 22 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
31. Remove second gear (1) from mainshaft (2).

32. Remove second gear bearing (1) from mainshaft

(2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 23

COUNTERSHAFT

NOTE: Bearings are the only component serviced

on the countershaft.

1. Remove countershaft rear housing bearing with

Puller 6444 (1), Plug 8513A (2), Puller Jaws 9597
(3) , Puller Collar 6444-8 (4), Puller Rods 6444-3
and Puller Flange 6444-1. Position Puller Jaws
9597 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.

3. Remove countershaft front housing bearing with

Puller 6444 (1), Puller Collar 6444-8 (2), Puller
Jaws 9597 (3), Puller Rods 6444-3 and Puller
Flange 6444-1. Position puller jaws around bearing
and puller flange. Position puller collar around the
puller jaws. Tighten the puller bolt and remove
countershaft bearing.
21 - 24 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
INPUT SHAFT

1. Position input shaft (1) mainshaft bearing seal (2)

in a vice then twist input shaft (1) out of the seal
(2).

2. Remove input shaft (1) bearing with Puller

C-293-PA (2) and Adapters C-293-47 (3).
3. Remove input shaft mainshaft bearing gasket.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 25

REAR HOUSING

1. Remove countershaft bearing cup and mainshaft

bearing cup with Puller 9593 (1) installed in cup
(2).

2. Install Remover 8915 (1) on puller (2) and tighten

remover nut (3) to pull cups out of the housing.
21 - 26 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
3. Remove output shaft seal (1) from housing (2) with
seal pick.

FRONT HOUSING
1. Remove countershaft bearing cup and mainshaft
bearing cup with Puller 9593 (1) installed in cup
(2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 27

2. Install Remover 8915 (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.

3. Remove input shaft retainer (1) bolts (2) and

remove retainer.

4. Remove input shaft seal (1) from retainer bore (2)

with a seal pick.
21 - 28 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
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 MOPART degreasing solvent, GunkT 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
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.

Synchronizer components: Inspect for worn,

chipped or cracked teeth and burned or flaking off fric-
tion 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.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 29
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.
Housing/Tail housing: Inspect sealing and mating
surfaces are free of burrs and nicks. Inspect alignment
dowels are tight and in good condition. Inspect shift
rail bushings for wear.

Input Retainer: Inspect release bearing slide surface

(2) and sealing surface.

ASSEMBLY
WARNING: Use welding gloves 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 - 177 Celsius (212° Min. - 350° 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.
21 - 30 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
INPUT SHAFT

1. Heat input shaft bearing (1) on bearing heater (2)

to a maximum of 177 Celsius (350° Fahrenheit).

2. Using welding gloves or tongs, install bearing (2)

on input shaft (1).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 31

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 177 Celsius
(350° Fahrenheit).
21 - 32 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
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 177 Celsius
(350° Fahrenheit).

5. Using welding gloves or tongs, install front housing

countershaft bearing (1) on countershaft (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 33

MAINSHAFT

1. Position mainshaft in Fixture 9605 mounted in vise.

2. Install second gear bearing (1) on mainshaft (2).

3. Install second gear (1) on mainshaft (2).

21 - 34 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
4. Install second gear stop ring (1) with teeth pointing
up on second gear (2).

5. Install second gear inner friction ring (1) on stop

ring (2).

6. Install second gear outer friction ring (1) on stop

ring (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 35

7. Install second gear blocker ring (1) on stop ring (2).

8. Install 1-2 synchronizer hub (1) on mainshaft and

synchronizer rings (2).

9. Install 1-2 synchronizer hub (1) and hub snap ring

(2).
21 - 36 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
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).

12. Install first gear blocker ring (1) on synchronizer

hub (2).

13. Install first gear outer friction ring (1) on synchro-

nizer hub (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 37

14. Install first gear inner friction ring (1) on synchro-

nizer hub (2).

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.

17. Install first gear (1) and bearing (2).

21 - 38 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
18. Heat thrust washer (1) and reverse gear bearing
race (2) on bearing heater to a maximum of 177
Celsius (350° Fahrenheit).

19. Using welding gloves or tongs, install thrust

washer (2) and reverse gear bearing race (1) on
mainshaft.

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

DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 39

21. Install reverse gear inner friction ring (1) on

reverse gear (2).

22. Install reverse gear outer friction ring (1) on inner

blocker ring (2).

23. Install reverse gear blocker ring (1) on friction ring

(2).
21 - 40 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
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 177 Celsius (350° Fahrenheit).

26. Using welding gloves or tongs, install mainshaft

(1) bearing (2) on mainshaft.
27. On 4x4 transmission install mainshaft (1) bearing
(2) snap ring.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 41

28. Install reverse synchronizer hub (1) detents (2).

29. Install reverse gear (2) synchronizer sleeve (1) on

hub and center sleeve on hub.

30. Turn mainshaft and Fixture 9605 over and secure

in vise.
31. Install third gear bearing (1) on mainshaft (2).
21 - 42 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
32. Install third gear (1) on mainshaft (2).

33. Install third gear stop ring (1) with teeth pointing
up on third gear (2).

34. Install third gear inner friction ring (1) on stop ring
(2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 43

35. Install third gear outer friction ring (1) on stop ring
(2).

36. Install third gear blocker ring (1) on stop ring (2).

37. Install 3-4 synchronizer hub (1) on third gear syn-

chronizer rings (2).
21 - 44 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
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).

41. Install fourth gear blocker ring (1) on synchronizer

hub (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 45

42. Install fourth gear outer friction ring (1) on syn-

chronizer hub (2).

43. Install fourth gear inner friction ring (1) on syn-

chronizer hub (2).

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.
21 - 46 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
46. Install fourth gear (1) and bearing (2).

47. Heat fourth gear thrust washer (1) on bearing

heater (2) to a maximum of 177 Celsius (350°
Fahrenheit).

48. Using welding gloves or tongs, install fourth gear

(1) thrust washer (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 47

49. Install fourth gear (1) snap ring (2).

50. Install sixth gear (1) and bearing (2) on mainshaft

(3).

51. Install sixth gear stop ring (1) on sixth gear (2).
21 - 48 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
52. Install sixth gear friction ring (1) on stop ring (2).

53. Install 5-6 synchronizer hub (1) on sixth gear syn-

chronizer rings (2).

54. Heat mainshaft bearing (1) on bearing heater to a

maximum of 177 Celsius (350° Fahrenheit).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 49

55. Using welding gloves or tongs, install mainshaft

bearing (1) on mainshaft.
56. Install mainshaft bearing (1) snap ring (2).

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).
21 - 50 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
59. Install fifth gear friction ring (1) onto hub (2).

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).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 51

REAR HOUSING

1. Install countershaft bearing cup with Installer 9589

(1) and Handle C-4171 (2).

2. Install mainshaft bearing cup with Installer 9588 (1)

and Handle C-4171 (2).
3. Install output shaft seal with Installer 9598.
21 - 52 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
4. Install reverse idler bearing (1) into idler gear (2).

5. Install idler gear (1) into rear housing (2) off to the
side. For mainshaft/countershaft installation
clearance.

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

DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 53

7. Install reverse (1), 1-2 (2) and 3-4 (3) shift rails and
forks as and assembly on synchronizer sleeves.

8. Install mainshaft with shift rails (2) into the rear

housing. Tilt the mainshaft then tilt the countershaft
(1) into the housing.

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 dur-

ing installation. Failure to follow these instructions
will result in cracking the oil slinger and lack of oil
to first/reverse bearing.
21 - 54 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
10. Position reverse idler gear and install idler shaft
(2) with bolt (1).

11. Install reverse idler gear shaft pin (1) into rear
housing (2) and tighten to 58 N·m (43 ft. lbs.).

12. Install 5-6 shift shoe narrow ends (1) into the 5-6
synchronizer sleeves (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 55

13. Install 5-6 shift fork (1) into the shift rail.

FRONT HOUSING
CAUTION: If mainshaft/bearings or countershaft/
bearings are replaced endplay measurements,
must taken to ensure proper bearing preload. Fail-
ure to follow these instruction will result in bear-
ing damage.

1. Install input shaft seal front housing bore (1) with

Installer 9595 (2).
21 - 56 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
2. Install input shaft retainer (1) and tighten bolts (2)
to 23 N·m (17 ft. lbs.).

3. Install select end play shims into the countershaft

bearing cup bore.
4. Install countershaft bearing cup with Installer 9589
(1) and Handle C-4171 (2).

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 9588 (1)
and Handle C-4171 (2).
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 57

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.).

10. Install 5-6 shift fork pins (1) into housing and
tighten to 58 N·m (43 ft. lbs.).

11. Push shift tower boot (1) onto shift tower (2).
21 - 58 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
12. Remove shift fork tie strap.
13. Apply Mopar™ Gasket Maker to the shift tower
opening.
14. Install shift tower (2) and tighten bolts (1) to 23
N·m (17 ft. lbs.).

15. Install back up lamp switch (1) and bolt (2).

INSTALLATION
1. Clean transmission front housing mounting surface.
2. Apply light coat of Mopar high temperature bearing
grease or equivalent to contact surfaces of follow-
ing components:
• release fork (1) ball stud (2)
• release bearing slide surface (3)
• input shaft splines (4)
• release bearing bore (5)
• propeller shaft slip yoke.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 59
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.).
• 5.7 L Engine: Install transmission top four 3/8
bolts and tighten to 41 N·m (30 ft. lbs.).

CAUTION: 5.7 L transmission bolts must be

installed in the following order. Failure to follow
these instructions will stress the engine and trans-
mission.

7. Install 5.7 L front dust shield bolts (3) and tighten to

54 N·m (40 ft. lbs.). On 5.7L if structural dust cover
was removed, install onto the transmission and
engine (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - INSTALLATION).
8. Install structural dust cover (1) 7/16 bolts (2) and
tighten to 68 N·m (50 ft. lbs.).
9. Install exhaust Y-pipe 5.7L engine.
21 - 60 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
10. Install crossmember and tighten nuts (2) to 102
N·m (75 ft. lbs.).
11. Install transmission mount bolts (1) and tighten to
68 N·m (50 ft. lbs.).

12. Install starter motor (1) 5.7L.

DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 61

13. Connect transmission harnesses to clips on case

and connect switches.
14. Install slave cylinder and tighten cylinder nuts to
23 N·m (200 in. lbs.).
15. Install transfer case and transfer case linkage 4x4
equipped.
16. Remove transmission jack.

17. Install propeller shaft/shafts with reference marks

aligned.
18. Install exhaust on the exhaust manifolds.
21 - 62 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
19. Remove fill plug (1) on transmission (2) and fill to
bottom edge of fill plug hole.
20. Install fill plug and tighten to 57 N·m (42 ft. lbs.).
21. Connect battery negative cable.
22. Install shift lever extension on shift tower and
lever assembly.
23. Slide boot down on shift lever extension and
install shift boot bezel and screws.
24. Install skid plate, if equipped.

ADJUSTMENTS
MAINSHAFT/COUNTERSHAFT BEARING PRELOAD
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
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 9592 (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.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 63
6. Place mainshaft shaft bearing cup on mainshaft
bearing.
7. Position Fixture 9592 (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.

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.
21 - 64 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR
COUNTERSHAFT

1. Remove countershaft bearing cup and shims from

the rear housing.
2. Position Fixture 9592 (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.

5. Place countershaft bearing cup on countershaft

bearing.
6. Position Fixture 9592 (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.
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 65

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
MANUAL TRANSMISSION-G56
TORQUE 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 Bolts 23 17 -
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 -

GEAR SPECIFICATIONS

GEAR RATIO
FIRST 6.29
SECOND 3.48
THIRD 2.10
FOURTH 1.38
FIFTH 1.00
SIXTH 0.79
REVERSE 5.74
21 - 66 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR

SPECIAL TOOLS

PULLER C-293-PA

PLUG 8513A

ADAPTERS C-293-47

REMOVER 8915

HANDLE C-4171

BRIDGE 938

PULLER 6444

INSTALLER 9588
DR MANUAL TRANSMISSION - G56 - SERVICE INFORMATION 21 - 67

INSTALLER 9589 INSTALLER 9595

MEASUREMENT FIXTURE 9592

JAWS 9597

PULLER 9593

INSTALLER 9598

PULLER 9594
21 - 68 MANUAL TRANSMISSION - G56 - SERVICE INFORMATION DR

FIXTURE 9605

PULLER 9646

PULLER 9647