Removal and Installation

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

REMOVAL
1. Disconnect the negative battery cable.
2. Raise and support the vehicle
3. Remove any necessary skid plates.
4. Mark propeller shaft and axle companion flanges for assembly alignment.
5. Remove the rear propeller shaft
6. Remove the front propeller shaft, if necessary.

Fig. 43:

7. Remove the engine to transmission collar (Fig. 43).
8. Remove the exhaust support bracket from the rear of the transmission.
9. Disconnect and lower or remove any necessary exhaust components.
10. Remove the starter motor.
11. 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.
12. Disconnect wires from solenoid and pressure switch assembly, input and output speed sensors, and line pressure sensor.

Fig. 44:

13. Disconnect gearshift cable from transmission manual valve lever (Fig. 44).
14. Disconnect transmission fluid cooler lines at transmission fittings and clips.
15. Disconnect the transmission vent hose from the transmission.
16. Support rear of engine with safety stand or jack.
17. Raise transmission slightly with service jack to relieve load on crossmember and supports.

Fig. 45:

18. Remove bolts securing rear support and cushion to transmission and crossmember (Fig. 45).
19. Remove bolts attaching crossmember to frame and remove crossmember.
20. Remove transfer case.
21. Remove all remaining converter housing bolts.
22. Carefully work transmission and torque converter assembly rearward off engine block dowels.
23. Hold torque converter in place during transmission removal.
24. Lower transmission and remove assembly from under the vehicle.
25. To remove torque converter, carefully slide torque converter out of the transmission.

INSTALLATION
1. Check torque converter hub and hub drive notches for sharp edges burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation.
2. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
3. Lubricate oil pump seal lip with transmission fluid.
4. Align converter and oil pump.
5. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.

Fig. 46:

6. Check converter seating with steel scale and straightedge (Fig. 46). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated.
7. Temporarily secure converter with C-clamp.
8. Position transmission on jack and secure it with chains.
9. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
10. Apply a light coating of Mopar High Temp Grease to the torque converter hub pocket in the rear
11. Raise transmission and align converter with drive plate and converter housing with engine block.
12. Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.
13. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.
14. Install two bolts to attach converter housing to engine.
15. Install remaining torque converter housing to engine bolts. Tighten to 68 Nm (50 ft. lbs.).
16. Install rear transmission crossmember. Tighten crossmember to frame bolts to 68 Nm (50 ft. lbs.).
17. Install rear support to transmission. Tighten bolts to 47 Nm (35 ft. lbs.).
18. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 Nm (35 ft. lbs.). Tighten the clevis bracket to rear support bolt to 68 Nm (50 ft. lbs.).
19. Remove engine support fixture.
20. Connect gearshift cable to transmission.
21. Connect wires to solenoid and pressure switch assembly connector, input and output speed sensors, and line pressure sensor. Be sure transmission harnesses are properly routed.

CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

22. Install torque converter-to-driveplate bolts. Tighten bolts to 31 Nm (270 in. lbs.).
23. Install starter motor and cooler line bracket.
24. Connect cooler lines to transmission.
25. Install transmission fill tube.
26. Install exhaust components.
27. Install transfer case. Tighten transfer case nuts to 35 Nm (26 ft. lbs.).
28. Install the transmission collar onto the transmission and the engine. Tighten the bolts to 54 Nm (40 ft. lbs.).
29. Align and connect propeller shaft(s).
30. Adjust gearshift cable if necessary.
31. Install any skid plates removed previously. Refer to Body and Frame, for the appropriate procedures.
32. Lower vehicle.
33. Fill transmission with Mopar ATF +4, type 9602 fluid.