Transmission Assembly Installation
INSTALLATION PROCEDURE
1. Install the rear transmission mount and install the bolts.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
2. Install the PNP switch and adjust as necessary. Install the PNP switch bolt.
^ Tighten the bolt to 10 Nm (7.5 ft. lbs.).
3. Install the manual shaft nut seal, the lock plate and the nut.
^ Tighten the nut to 5 Nm (44 inch lbs.).
4. Stake the lock plate.
5. Install the 2 bell housing studs.
6. Install transmission.
7. Install upper bell housing bolts.
^ Tighten the bolts to 85 Nm (62 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
8. With the aide of an assistant, install the transfer case and the bolts (1) (if 4WD equipped).
^ Tighten the bolts to 31 Nm (23 ft. lbs.).
9. Install the transmission wire harness, the retainer, and the bolt.
10. Connect the electrical connectors and the vent tubes to the transmission and the transfer case (If 4WD equipped).
11. Install the crossmember (7) and the crossmember bolts (3,5,6).
^ Tighten the crossmember bolts to 60 Nm (44 ft. lbs.).
12. Install the ground wire and the ground wire bolt to the transfer case mount.
^ Tighten the ground wire bolt to 7 Nm (62 inch lbs.).
13. Install speedometer cable (2), the speedometer cable bracket, and the bolt (1) to the transfer case (if 4WD equipped).
14. Install the transfer case skid plate (2) and the bolts (1,4) (if 4WD equipped).
15. Remove the jack from the transmission.
16. Install the cooler hoses (1,2) and the clamps (5,6) to the transmission cooler pipes (3,4).
17. Install the lower bellhousing nuts.
^ Tighten the lower bellhousing nuts to 85 Nm (62 ft. lbs.).
18. Install the torque converter bolts.
^ Tighten the torque converter bolts to 50 Nm (37 ft. lbs.).
19. Install the flywheel inspection cover plate (1) and the bolts (2).
^ Tighten the flywheel inspection cover plate bolts to 10 Nm (89 ft. lbs.).
20. Install the engine brace (1) and the bolts (2) to the left side of the transmission.
^ Tighten the engine brace bolts to 60 Nm (44 ft. lbs.).
21. Install the starter and the lower bolt.
^ Tighten the starter lower bolt to 30 Nm (22 ft. lbs.).
22. Connect the starter electrical connections.
23. Install the following components:
^ The catalytic converter seal
^ The gasket
^ The converter assembly
^ The springs (2)
^ The flange bolts
^ Tighten the flange bolts to 50 Nm (37 ft. lbs.).
24. Install the exhaust front hanger (1).
25. Install the nuts which secure the converter to the exhaust pipe.
26. Install the oxygen sensor to the exhaust.
^ Tighten the oxygen sensor to 9 Nm (80 ft. lbs.).
27. Install the exhaust hanger and the 02 sensor harness to the crossmember.
28. Install the fluid indicator tube (1), the bolt (2), and the O-ring seal.
29. Install the shift cable bracket and the bolts.
^ Tighten the shift cable bolts to 7 Nm (62 ft. lbs.).
30. Install the shift cable to manual lever (2).
31. Install the shift cable and retainer (4) to the cable (3) bracket (1).
32. Install the rear propeller shaft, the bolts, and the nuts to the flange (1).
^ Tighten the rear propeller shaft bolts and nuts to 50 Nm (37 ft. lbs.).
33. Install the front propeller shaft, the bolts, and the nuts to the flange (1) (If 4WD equipped).
^ Tighten the front propeller shaft bolts and nuts to 50 Nm (37 ft. lbs.).
34. Fill the transfer case (if 4WD equipped).
35. Lower the vehicle.
36. Install the upper starter bolt (1), the nut, and the ground wire.
37. Install the fluid indicator.
38. Route the T.V. cable (2) to the upper engine.
39. Install the throttle body cover and screws. Adjust the T.V. cable as necessary.
40. If the vehicle is equipped with 4WD, perform the following steps: .
40.1. Install the transfer case shifter boot clamp, the #1 boot and-the transfer case shifter assembly.
40.2. Install the transfer case boot cover and the #2 boot.
40.3. Install the transfer case boot cover screws.
40.4. Install the gear shift control lever knob (1) and the screw to the gearshift control lever.
41. Install the center front console while connecting the electrical connectors. Install the screws and the clips.
42. Install the center rear console and connect the electrical connectors. Install the screws and the clips.
43. Adjust the shift cable as necessary.
44. Refill the transmission fluid and inspect for leaks.
Refer to Transmission Fluid Checking Procedure in Testing and Inspection.
45. Test the transmission for proper installation.