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Tr6060 Manual Transmission (Service Information): Disassembly: Notes

Position the transmission over a suitable drain pan and empty the lubricant. Place the transmission on a stable work surface. If the bellhousing is attached to the transmission, remove the bellhousing.

GC0135819Courtesy of CHRYSLER GROUP, LLC
  1. Remove the bolts (2) holding the shift cover to the extension housing.
  2. Separate the shift cover (1) from the extension housing.
    GC0135820Courtesy of CHRYSLER GROUP, LLC
  3. Using a suitable hammer and punch, remove the roll pin (2) holding the offset lever (1) to the shaft rail.
    GC0135821Courtesy of CHRYSLER GROUP, LLC
  4. Remove the offset lever (1) from the shift rail (2).
    GC0135822Courtesy of CHRYSLER GROUP, LLC
  5. Remove the nuts (2) holding the top of the extension housing (1) to the transmission.
    GC0156649Courtesy of CHRYSLER GROUP, LLC
  6. Remove the bolts (2) holding the extension housing (1) to the transmission.
    GC0135824Courtesy of CHRYSLER GROUP, LLC
  7. Pry the extension housing (1) from the transmission (2) at the pry points.
    GC0156809Courtesy of CHRYSLER GROUP, LLC
  8. Remove the bolts holding the clutch release bearing to the transmission.
  9. Separate the clutch release bearing from the transmission.
    GC0156597Courtesy of CHRYSLER GROUP, LLC
  10. Remove all but two of the bolts holding the input shaft adapter housing to the transmission.
  11. Place the tool (special tool #9387, Fixture, Transmission Holding) in position on the front of the transmission.
  12. Install four bolts to hold the fixture to the bellhousing mount locations on the transmission.
    GC0156712Courtesy of CHRYSLER GROUP, LLC
  13. Insert transmission fixture into the tool (special tool #9385, Holding Fixture, Bench Mount) that is bolted to a suitable work bench.
    GC0156488Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the output shaft packing (1) is damaged, it does not require replacement. It can be discarded.

  14. Remove the output shaft (2) packing (1).
    GC0135825Courtesy of CHRYSLER GROUP, LLC
  15. Remove the snap ring (1) holding the roller bearing (2) to the mainshaft.
    GC0135826Courtesy of CHRYSLER GROUP, LLC
  16. Remove the roller bearing (1) and spacers (2) from the mainshaft.
    GC0135827Courtesy of CHRYSLER GROUP, LLC
  17. Remove the snap ring (2) holding the reverse gear on the mainshaft.
    GC0135828Courtesy of CHRYSLER GROUP, LLC
  18. Remove the reverse gear thrust washer (2) from the mainshaft.
    GC0135829Courtesy of CHRYSLER GROUP, LLC
  19. Remove the reverse gear (1) from the mainshaft (2).
    GC0135830Courtesy of CHRYSLER GROUP, LLC
  20. Remove the reverse gear bearing (1) from the mainshaft (2).
    GC0135831Courtesy of CHRYSLER GROUP, LLC
  21. Remove the reverse synchronizer rings (1) from the reverse synchronizer hub.
    GC0135832Courtesy of CHRYSLER GROUP, LLC
  22. Remove the snap ring (2) holding the reverse synchronizer hub (1) on the mainshaft.
    GC0135833Courtesy of CHRYSLER GROUP, LLC
  23. Remove the snap ring (2) holding the reverse shift fork on the shift rail (discard snap ring)  .
    NOTE:

    If necessary, the sleeve and detents can be removed separately from the mainshaft.

    GC0135834Courtesy of CHRYSLER GROUP, LLC
  24. Remove the reverse shift fork (1), synchronizer hub, and sleeve (2) from the mainshaft as an assembly if possible.
    GC0135835Courtesy of CHRYSLER GROUP, LLC
  25. Remove the snap ring (2) holding the reverse gear (1) on the countershaft.
    GC0135836Courtesy of CHRYSLER GROUP, LLC
  26. Using a typical three jaw puller (2) and (special tool #10027, Button, Press), pull the reverse gear (1) from countershaft.
    GC0135837Courtesy of CHRYSLER GROUP, LLC
  27. Remove the snap ring (1) holding the fifth gear thrust washer (2) on the countershaft.
    GC0135838Courtesy of CHRYSLER GROUP, LLC
  28. Remove the fifth gear thrust washer (1) from the countershaft (2).
    GC0135839Courtesy of CHRYSLER GROUP, LLC
  29. Remove fifth gear (1) from the countershaft (2).
    GC0135840Courtesy of CHRYSLER GROUP, LLC
  30. Remove the fifth gear bearing (1) from countershaft (2).
    GC0135841Courtesy of CHRYSLER GROUP, LLC
  31. Remove the fifth gear bearing spacer (1) from countershaft (2).
    GC0135842Courtesy of CHRYSLER GROUP, LLC
  32. Remove the fifth gear synchronizer rings (1) from the 5-6 synchronizer hub (2).
    GC0135843Courtesy of CHRYSLER GROUP, LLC
  33. Remove the retainer (1) holding the split ring on fifth gear and the mainshaft (2).
    GC0135844Courtesy of CHRYSLER GROUP, LLC
  34. Remove the split rings (1) holding fifth gear on the mainshaft (2).
    GC0135845Courtesy of CHRYSLER GROUP, LLC
  35. Using tools (special tool #9382, Bridge), (special tool #9378, Bolts, Puller), (special tool #10027, Button, Press) and (special tool #9379a, Remover, Gear), remove fifth gear (4) from the mainshaft.
    GC0135846Courtesy of CHRYSLER GROUP, LLC
  36. Remove the snap ring (1) holding the 5-6 gear shift fork on the shift rail (2).
    GC0135847Courtesy of CHRYSLER GROUP, LLC
  37. Remove snap ring (1) holding the 5-6 synchronizer hub on the countershaft.
    GC0135848Courtesy of CHRYSLER GROUP, LLC
  38. While pulling or prying upward on the 5-6 shaft fork (1), remove the synchronizer sleeve (2), and detents (3) from the 5-6 synchronizer hub.
    GC0135849Courtesy of CHRYSLER GROUP, LLC
  39. Using tools (special tool #9382, Bridge) (1), (special tool #9378, Bolts, Puller) (2), (special tool #10027, Button, Press) and (special tool #10026, Puller, Synchro Hub) (3), remove the 5-6 synchronizer hub from the countershaft.
    GC0135850Courtesy of CHRYSLER GROUP, LLC
  40. Remove the synchronizer rings (1) from sixth gear (2).
    GC0135851Courtesy of CHRYSLER GROUP, LLC
  41. Remove sixth gear (1) from the countershaft (2).
    GC0135852Courtesy of CHRYSLER GROUP, LLC
  42. Remove the sixth gear bearing (1) from the countershaft (2).
    GC0135853Courtesy of CHRYSLER GROUP, LLC
  43. Remove the sixth gear bearing spacer (1) from the countershaft (2).
    GC0135854Courtesy of CHRYSLER GROUP, LLC
  44. Remove the bolts holding the top cover (1) to the transmission housing (2).
  45. Separate the top cover (1) from the transmission (2).
    GC0135855Courtesy of CHRYSLER GROUP, LLC
  46. Remove shift detent plug (1) from the right side of transmission (2).
    GC0135856Courtesy of CHRYSLER GROUP, LLC
  47. Remove the skip shift solenoid (1) from the left side of transmission (2).
    GC0135857Courtesy of CHRYSLER GROUP, LLC
  48. Using a suitable pin-punch, drive the roll pin downward until the skip shift lever (1) is free on the shift rail (2).
    GC0135858Courtesy of CHRYSLER GROUP, LLC
  49. Remove plug (1) holding the roller detent in the transmission adapter (2).
    GC0135859Courtesy of CHRYSLER GROUP, LLC
  50. Extract the roller detent (1) and spring (2) from the bore in the transmission adapter.
    GC0135860Courtesy of CHRYSLER GROUP, LLC
  51. Remove the shift lever guide bolts (2) from the top of transmission housing (1).
    GC0135861Courtesy of CHRYSLER GROUP, LLC
  52. Remove the remaining bolts (3) holding the input shaft adapter (2) to the transmission housing.
    GC0135862Courtesy of CHRYSLER GROUP, LLC
  53. Lift the transmission housing (1) upward and off of the input shaft adapter plate (2) and remove skip shift lever from shift rail.
    GC0135863Courtesy of CHRYSLER GROUP, LLC
  54. Remove reverse shift rail (2) assembly from input shaft adapter plate (3).
    GC0156808Courtesy of CHRYSLER GROUP, LLC
  55. Tilt the countershaft (4) sideways, then remove the mainshaft (1) and the shift rail (2) from the adapter plate (3).
  56. Remove the countershaft (4) assembly from the adapter plate.
    GC0135865Courtesy of CHRYSLER GROUP, LLC
  57. Remove the input shaft synchronizer ring (1) and the input shaft (2) from transmission adapter.
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