Installation

NV4500 - Manual Transmission
INSTALLATION

NOTE: If a new transmission is being installed, 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 or equivalent to contact surfaces of the 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.).
8. Install transmission mount on transmission or rear crossmember.
9. Install rear crossmember.
10. Remove transmission jack and engine support fixture.
11. Position transmission harness wires in clips on shift cover.
12. Install clutch slave cylinder and install slave cylinder shield, if equipped.
13. Connect speed sensor and backup light switch wires.





FOUR WHEEL DRIVE
1. Install transfer case shift mechanism on transmission.
2. Install transfer case on transmission jack. Secure transfer case to jack with safety chains.
3. Raise jack and align transfer case input gear with transmission mainshaft.
4. Move transfer case forward and seat it on adapter.
5. Install and tighten transfer case attaching nuts.
Tighten nuts to 41 - 47 Nm (30 - 35 ft. lbs.) if case has 3/8 studs or
30 - 41 Nm (22 - 30 ft. lbs.) if case has 5/16 studs.

6. Install transfer case shift mechanism to side of transfer case.
7. Connect transfer case shift lever to range lever on transfer case.
8. Align and connect propeller shafts.
9. Fill transmission with required lubricant. Check lubricant level in transfer case and add lubricant if necessary.
10. Install transfer case skid plate, if equipped and crossmember.
Tighten attaching bolts/nuts to 41 Nm (30 ft. lbs.).

11. Install exhaust system components.
12. Lower vehicle.
13. Clean the mating surfaces of shift tower, isolator plate and shift cover with suitable wax and grease remover.
14. Apply Mopar Gasket Maker or equivalent to the sealing surface of the shift cover. Do not over apply sealant.
15. Install the isolator plate onto the shift cover, metal side down.
16. Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and the isolator plate.
17. Verify that the shift tower, isolator plate and the shift tower bushings are properly aligned.
18. 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.).

19. Install the shift lever extension onto the shift tower and lever assembly.
20. Install shift lever boot and bezel.
21. Connect battery negative cable.