NV4500 - Manual Transmission
REMOVAL1. Disconnect battery negative cable.
2. Shift transmission into Neutral.
3. Remove screws attaching shift boot to floorpan. Then slide boot upward on the shift lever.
4. Remove the shift lever extension from the shift tower and lever assembly.
5. Remove the bolts holding the shift tower to the isolator plate and transmission shift cover.
6. Remove the shift tower and isolator plate from the transmission shift cover.
7. Raise and support vehicle.
8. Mark propeller shaft and axle yokes for alignment reference. Use paint, scriber, or chalk to mark yokes.
9. Remove propeller shaft.
10. Disconnect and remove exhaust system Y-pipe.
11. Disconnect wires at speed sensor and backup light switch.
12. Support engine with adjustable safety stand and wood block.
Fig. 9:
13. If transmission is to be disassembled for repair, remove drain bolt at bottom of PTO cover and drain lubricant from transmission (Fig. 9).
14. Remove bolts/nuts attaching transmission to rear mount.
15. Support transmission with a transmission jack. Secure transmission to jack with safety chains.
16. Remove rear crossmember.
17. Remove bolts attaching clutch slave cylinder to clutch housing. Then move cylinder aside for working clearance.
18. Remove transmission harness wires from clips on transmission shift cover.
19. Remove bolts attaching transmission to clutch housing.
20. Slide transmission and jack rearward until input shaft clears clutch housing.
21. Lower transmission jack and remove transmission from under vehicle.
INSTALLATION
NOTE: If a new transmission is being installed, be sure to use all components supplied with the new transmission. For example, if a new shift tower is supplied with the new transmission, do not re-use the original shift tower.
1. Apply light coat of Mopar high temperature bearing grease to contact surfaces of following components:
^ input shaft splines.
^ release bearing slide surface of front retainer.
^ release bearing bore.
^ release fork.
^ release fork ball stud.
^ propeller shaft slip yoke.
2. Apply sealer to threads of bottom PTO cover bolt and install bolt in case.
3. Mount transmission on jack and position transmission under vehicle.
4. Raise transmission until input shaft is centered in release bearing and clutch disc hub.
5. Move transmission forward and start input shaft in release bearing, clutch disc and pilot bushing.
6. Work transmission forward until seated against clutch housing. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
7. Install and tighten transmission-to-clutch housing bolts to 108 Nm (80 ft. lbs.) torque.
8. Install clutch slave cylinder.
9. Connect speed sensor and backup light switch wires.
10. Fill transmission with recommended lubricant. Correct fill level is bottom edge of fill plug hole.
11. Position transmission harness wires in clips on shift cover.
12. Install transmission mount on transmission or rear crossmember.
13. Install rear crossmember.
14. Remove transmission jack and engine support fixture.
15. Align and install propeller shaft.
16. Lower vehicle.
17. Clean the mating surfaces of shift tower, isolator plate, and shift cover with suitable wax and grease remover.
18. Apply Mopar Gasket Maker, or equivalent, to the sealing surface of the shift cover. Do not over apply sealant.
19. Install the isolator plate onto the shift cover, metal side down.
20. Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and the isolator plate.
21. Verify that the shift tower, isolator plate, and the shift tower bushings are properly aligned.
22. Install the bolts to hold the shift tower to the isolator plate and the shift cover. Tighten the shift tower bolts to 10.2 - 11.25 Nm (7.5 - 8.3 ft. lbs.).
23. Install the shift lever extension onto the shift tower and lever assembly.
24. Install shift boot and bezel.
25. Connect battery negative cable.