Transmission Replacement
Transmission Replacement (With 6.6L (LB7) Engine)^ Tools Required
- J 21366 Converter Holding Strap
- J 44257 Main Wiring Harness Connector Remover
Removal Procedure
Important: If replacing a failed transmission with a replacement unit, it is important to reset the Transmission Control Module (TCM) to base calibration and fast adaptive for all shifts.
1. Disconnect the negative battery cable.
2. Remove the fluid level indicator.
3. Raise the vehicle halfway.
Notice: The torque converter bolts can be accessed only through the starter motor opening. Remove the torque converter bolts before removing the transmission support in order to ensure that the transmission is supported properly during this procedure. Failure to support the transmission properly may result in vehicle damage.
4. Remove the starter motor bolts and position the starter motor aside towards the front of the vehicle.
5. Using the front crankshaft bolt, rotate the engine to align the torque converter bolts with the starter motor opening. Use an adjustable wrench on the front crankshaft bolt. Have an assistant rotate the engine while aligning the bolts.
6. Mark the flywheel and torque converter relationship for reassembly purposes.
7. Remove the torque converter bolts, gaining access through the right wheel well opening.
8. Raise the vehicle.
9. Drain the transmission fluid, if necessary.
10. Remove the rear propeller shaft.
11. If equipped with 4-wheel drive (4WD), remove the front propeller shaft.
12. Support the transmission with a transmission jack.
13. Remove the two nuts securing the transmission mount to the transmission support.
14. Remove the transmission support nuts and bolts.
15. Remove the transmission support from the vehicle.
16. Remove the transmission mount.
17. Remove the transfer case, if equipped with 4WD.
^ If equipped with a NVG 261-NP2, refer to Transfer Case Assembly Replacement.
^ If equipped with a NVG 263-NP1, refer to Transfer Case Assembly Replacement.
18. Remove the shift cable from the selector lever ball stud (5) and bracket (3).
19. Remove the shift cable bracket (2) from the transmission.
20. Remove the bolts from the fuel line retainers (1) on the left side of the transmission.
21. Remove the nut from the stud that retains the fuel line bracket to the converter housing.
22. Disconnect the electrical connectors from the turbine speed sensor (1) and the input speed sensor (2).
23. Disconnect the electrical connector from the output speed sensor (3). If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and will already be disconnected.
24. Remove the main electrical connector from the transmission using the J 44257.
25. Disconnect the electrical connectors from the park/neutral position switch.
26. Remove the transmission heat shield.
27. Secure the transmission safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other related components that may still be connected to the vehicle.
28. Disconnect the transmission oil cooler lines (1, 2) from the transmission.
29. Plug the transmission oil cooler line fittings in the transmission case.
30. If the vehicle is equipped with a power take off unit (PTO), disconnect and/or remove the necessary components to facilitate transmission removal.
31. Remove the nuts from the studs on the converter housing and position aside the fill tube.
32. Remove the nut from the stud on the converter housing and position aside the wire harness/vent tube retaining bracket.
33. Remove the remaining bolts and studs from the converter housing.
34. Separate the transmission from the engine.
35. Install the J 21366 to the transmission converter housing in order to keep the torque converter from sliding off of the transmission turbine shaft.
36. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
Installation Procedure
1. Install the J21366 in order to keep the torque converter from sliding off of the transmission turbine shaft.
2. Raise the transmission into place while simultaneously installing the fill tube.
3. Remove the J 21366.
4. Align the transmission with the engine using the alignment dowels located at the rear of the engine.
5. Ensure that the torque converter can be rotated before tightening the studs and bolts.
Important: Do not install the transmission by drawing it to the engine using the studs and bolts.
6. Make sure the transmission is flush against the engine.
Notice: Refer to Fastener Notice in Service Precautions.
7. Install the studs and bolts that secure the transmission to the engine.
^ Tighten the studs and bolts to 50 Nm (37 ft. lbs.).
8. Install the wire harness/vent tube retaining bracket to the stud on the converter housing. Install the nut to the stud that retains the bracket.
^ Tighten the nut to 18 Nm (13 ft. lbs.).
9. Install the fill tube to the studs on the converter housing.
Install the nuts to the studs that retain the fill tube.
^ Tighten the nuts to 18 Nm (13 ft. lbs.).
10. Remove the transmission safety chain from around the transmission.
11. If the vehicle is equipped with a Power Take Off Unit (PTO), connect and/or install the components at this time.
12. Install the transmission heat shield.
13. Connect the electrical connectors to the park/neutral position switch.
14. Install the main electrical connector (2) to the transmission.
15. Connect the electrical connector to the output speed sensor (3). This sensor is located on the transfer case if the vehicle is equipped with 4WD, and will be connected during transfer case installation.
16. Connect the electrical connectors to the turbine speed sensor (1) and the input speed sensor (2).
17. Install the fuel line bracket to the stud on the transmission converter housing.
18. Install the nut to the converter housing stud that retains the fuel line bracket.
^ Tighten the nut to 18 Nm (13 ft. lbs.).
19. Install the fuel line retainers (1) and bolts to the left side of the transmission.
^ Tighten the bolts to 2.5 Nm (22 inch lbs.).
20. Install the shift cable bracket (2) to the transmission.
21. Install the shift cable bracket bolts to the transmission.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
22. Install the shift cable (2) to the bracket (3) and the selector lever ball stud (5).
23. Install the transfer case, if equipped with 4WD.
^ If equipped with a NVG 261-NP2, refer to Transfer Case Assembly Replacement.
^ If equipped with a NVG 263-NP1, refer to Transfer Case Assembly Replacement.
24. Install the transmission mount to the transmission. If equipped with 4WD, the transmission mount will be mounted to the transfer case adapter.
25. Install the transmission mount bolts.
^ For 4WD vehicles, tighten the bolts to 47 Nm (35 ft. lbs.).
^ For 2WD vehicles, tighten the bolts to 50 Nm (37 ft. lbs.).
26. Install the transmission support to the vehicle.
27. Install the transmission support nuts and bolts.
^ Tighten the nuts and bolts to 70 Nm (52 ft. lbs.).
28. Lower the transmission.
29. Install the two nuts securing the mount to the transmission support.
^ Tighten the nuts to 40 Nm (30 ft. lbs.).
30. Remove the transmission jack
31. If equipped with a transfer and install the front propeller shaft.
32. Install the rear propeller shaft.
33. Lower the vehicle halfway.
34. Remove the access bloke cover (1) on the converter housing to rotate the converter and align the first torque converter bolt. Use the marks made during disassembly.
35. Install the torque converter bolts, gaining access through the right wheel well opening.
^ Tighten the bolts to 60 Nm (44 ft. lbs.).
36. Install the converter housing access stole cover.
37. Install the starter motor.
38. Flush the transmission oil cooler and lines If necessary.
39. Connect the transmission oil cooler lines to the transmission.
40. Lower the vehicle.
41. Connect the negative battery cable.
42. Fill the transmission to the proper level with approved fluid.
43. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. Fast Learn Procedure