Transmission Replacement

TRANSMISSION REPLACEMENT

Tools Required: J 35944-A Transmission Oil Cooler Flusher

Removal Procedure

Important: Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

1. Raise and support the vehicle.





2. Remove the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan.
3. Remove the powertrain (engine, transmission, frame) from the vehicle. Engine Replacement





4. Remove the fluid filler tube nut from the exhaust gas recirculation (EGR) valve.
5. Remove the fluid filler tube bolt from the transaxle.
6. Remove the fluid filler tube.





7. Remove the transmission bell housing bolts (2).





8. Remove the transaxle brace bolts.
9. Remove the transaxle brace.
10. If the vehicle is equipped with AWD (M76), remove the transaxle brace bolts and nuts.
11. Remove the transaxle brace.
12. Remove the coolant inlet pipe. Service and Repair
13. Use a utility stand with a block of wood in order to support the transaxle.





14. Remove the transaxle mount upper nuts.





15. Remove the transaxle mount bracket bolts.
16. Remove the transaxle mount bracket.





17. If equipped with LX9, remove the starter motor bolts.
18. Remove the starter motor.





19. If equipped with LY7, remove the starter motor bolts.
20. Remove the starter motor.
21. Remove the torque converter bolts. Service and Repair





22. Remove the transmission upper brace nut located behind the power steering pump and above the transfer case.





23. Remove the transmission upper brace bolts (1, 2).
24. Remove the transmission upper brace.





25. Remove the transmission bolt near the crank sensor and the engine coolant (block) heater.
26. Separate the transmission from the engine.
27. Install the transaxle to the transmission support fixture. Overhaul
28. If the vehicle is equipped with AWD (M76), remove the transfer case. Overhaul
29. Flush the transaxle oil cooler and the transaxle oil cooler hoses.

Installation Procedure

Important: If you are replacing the transaxle, transfer case or any internal components, you must inspect the end play and adjust as needed.

1. If the vehicle is equipped with AWD (M76), install the transfer case.
2. Remove the transmission support fixture.





3. Use the dowel locator pins (1) in order to align and install the transmission to the engine.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the transmission bell housing bolts (2).

Tighten
-> Transmission bell housing bolts to 50 Nm (37 lb ft).





5. Install the transmission bell housing bolt near the crank sensor and the engine coolant (block) heater.

Tighten
-> Transmission bell housing bolt to 50 Nm (37 lb ft).





6. Install the transmission upper brace.
7. Install the transmission upper brace bolts.

Tighten
-> Transmission upper brace outboard bolts (2) to 23 Nm (17 lb ft).
-> Transmission upper brace inboard bolts (1) to 50 Nm (37 lb ft).





8. Install the transmission upper brace nut located behind the power steering pump and above the transfer case.

Tighten
-> Transmission upper brace nut to 50 Nm (37 lb ft).
-> Install the torque converter bolts.





10. If equipped with LX9, install the starter motor.
11. Install the starter motor bolts.

Tighten
-> Starter motor bolts to 40 Nm (30 lb ft).





12. If equipped with LY7, install the starter motor.
13. Install the starter motor bolts.

Tighten
-> Starter motor bolts to 50 Nm (37 lb ft).

14. Position the transaxle mount bracket.





15. Install the transaxle mount bracket bolts.

Tighten
-> Start with the forward lower bolt and work clockwise to tighten the transaxle mount bracket bolts to 95 Nm (70 lb ft).

16. Remove the utility stand.





17. Install the transaxle mount upper nuts.

Tighten
-> Transaxle mount upper nuts to 47 Nm (35 lb ft).

18. Install the coolant inlet pipe.
19. If the vehicle is equipped with AWD (M76), install the transfer case brace.
20. Install the transfer case brace bolts and nuts.

Tighten
-> Transfer case brace bolts to 50 Nm (37 lb ft).
-> Transfer case brace nuts to 50 Nm (37 lb ft).





21. Install the transaxle brace.
22. Install the transaxle brace bolts.

Tighten
-> Bolts to 43 Nm (32 lb ft).





23. Use the dowel locator pins (1) in order to align and install the transmission to the engine.
24. Install the bell housing bolts (2).

Tighten
-> Bolts to 50 Nm (37 lb ft).





Important: Do NOT place the fluid filler tube seal on the fluid filler tube when installing the tube or damage to the seal will result.

25. Install the fluid filler tube seal in the transaxle.
26. Install the filler tube.





27. Install the fluid filler tube bolt.

Tighten
-> Bolt to 13 Nm (115 lb. in).

28. Install the fluid filler tube nut.

Tighten
-> Nut to 13 Nm (115 lb in).

29. Install the powertrain (engine, transmission, frame) to the vehicle.





30. Install the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan.

Tighten
-> Transmission bell housing bolt to 50 Nm (37 lb ft).

31. Lower the vehicle.
32. Inspect and adjust the transaxle fluid level as needed. Refer to the following information:
-> Transmission Fluid Check Service and Repair
-> Fluid and Lubricant Recommendations Fluid Type Specifications
-> Approximate Fluid Capacities Capacity Specifications

Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

33. Reset the TAP values. Transmission Adaptive Functions