Removal and Replacement

CAUTION: The transmission and torque converter must be removed as an assembly to avoid component damage. The converter drive plate, pump bushing, or oil seal can be damaged if the converter is left attached to the drive plate during removal. Be sure to remove the transmission and converter as an assembly.

REMOVAL
1. Disconnect battery negative cable.
2. Remove engine to transmission bending braces.
3. Remove starter motor and cooler line bracket.

CAUTION: The crankshaft position sensor can be damaged if the transmission is removed (or installed) with the sensor still bolted to the engine block. To avoid damage, remove the sensor before removing the transmission.

4. Disconnect and remove crankshaft position sensor. Retain sensor attaching bolts.
5. Remove torque converter access cover.
6. Remove transmission oil pan and drain fluid. Temporarily install pan after fluid is drained.
7. Remove transmission fluid fill tube. Discard fill tube seal, it should not be reused.
8. Mark torque converter and drive plate for assembly alignment. Use scriber or paint for this purpose.
9. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.

Fig. 13:

10. Mark propeller shaft and axle yokes for assembly alignment. Then disconnect and remove propeller shaft (Fig. 13).
11. Disconnect wires from [1][2]park/neutral position switch and transmission solenoid.
12. Disconnect gearshift cable from transmission shift lever.
13. Disconnect throttle valve cable from transmission throttle lever.
14. Remove transmission wire harnesses from clips on transmission. Also disconnect oxygen sensor wire if necessary.

Fig. 14:

15. Install engine support fixture Tool C-3487-A with frame hooks (or a suitable substitute) to support rear of engine (Fig. 14).
16. Raise transmission slightly with service jack to relieve load on supports.
17. Remove bolts securing transmission mount to crossmember and crossmember to frame and remove crossmember.
18. Remove engine oil filter.
19. Remove all converter housing bolts.
20. Disconnect fluid cooler lines at transmission.

CAUTION: Do not dip front of transmission downward during removal process, torque converter can fall out causing damage or injury.

21. Carefully work transmission and torque converter assembly rearward off engine block dowels and disengage torque converter hub from end of crankshaft. If necessary, attach a small C-clamp to edge of bell housing to hold torque converter in place during transmission removal.
22. Lower transmission and remove assembly from under the vehicle.

INSTALLATION
1. Position transmission on jack and secure it with chains.
2. Check condition of converter drive plate. Replace if plate if cracked, distorted or damaged.
3. Be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
4. Raise transmission and align converter with drive plate.
5. Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.
6. Rotate converter so alignment marks scribed on converter are aligned with mark on drive plate.
7. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.

Fig. 15:

8. Install bolts attaching converter housing to engine (Fig. 15).

Fig. 16:

9. Install rear support (Fig. 16). Then lower transmission onto crossmember and install bolts attaching transmission mount to crossmember.
10. Connect transmission cooler lines.
11. Remove engine support fixture.
12. Install crankshaft position sensor.
13. Secure wire harnesses to clips on transmission. Connect oxygen sensor if necessary.
14. Connect gearshift and throttle valve cables to levers on transmission.
15. Connect wires to [1][2]park/neutral position switch, and transmission solenoid(s). Be sure transmission harnesses are properly routed.

CAUTION: It is essential that correct length bolts be used to attach the converter to the drive plate. Bolts that are too long will damage the lockup surface within the converter. If new bolts are required, use the bolts specified in this procedure and in the parts book only.

16. Verify converter bolt length. Bolt measurement is from bottom (underside) of bolt head to end of bolt threads.
- 9.5 inch 3-lug converter bolts are 11.7 mm (0.46 inch).
- 9.5 inch 4-lug converter bolts are 13.2 mm (0.52 inch).
- 10.0 inch 4-lug converter bolts are 13.2 mm (0.52 inch).
- 10.75 inch 4-lug converter bolts are 11.2 mm (0.44 inch).
17. Install and tighten torque converter-to-drive plate bolts to following torque:
- 9.5 inch 3-lug converter bolts to 54 Nm (40 ft. lbs.).
- 9.5 inch 4-lug converter bolts to 74 Nm (55 ft. lbs.).
- 10.0 inch 4-lug converter bolts to 74 Nm (55 ft. lbs.).
- 10.75 inch 4-lug converter bolts to 31 Nm (270 inch lbs.).
18. Install converter housing access cover.
19. Install starter motor and cooler line bracket.
20. Install transmission fill tube. Install new seal on tube before installation.
21. Align and install propeller shaft.
22. Adjust gearshift and throttle valve cables if necessary.
23. Lower vehicle.
24. Fill transmission with MOPAR ATF+4, Type 9602 fluid.