Installation

INSTALLATION / NV3500 Manual Transmission

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 drain plug, then install plug in case.
3. Mount transmission on jack and position transmission under vehicle. Secure transmission to jack with safety chains.
4. Raise transmission until input shaft is centered in clutch disc hub.
5. Move transmission forward and start input shaft in clutch disc.
6. Work transmission forward until seated against engine. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
7. Install and tighten transmission to engine bolts to 108 Nm (80 ft. lbs.).

8. Position transmission harness wires in clips on shift cover.
9. Install slave cylinder and shield, if equipped.
10. Install transmission mount on transmission or rear crossmember.




4WD
1. Install transfer case shift lever on transmission.
2. Install rear crossmember.

NOTE: Ensure wiring harness is clear before installing crossmember.

3. Remove transmission jack and engine support fixture.
4. Install transfer case on transmission jack. Secure transfer case to jack with safety chains.
5. Raise jack and align transfer case input gear with transmission output shaft.
6. Move transfer case forward and seat it on transmission.
7. 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.

8. Connect backup light switch wires.
9. Install transmission dust cover.
10. Install starter.
11. Install transfer case shift lever to side of transfer case.
12. Connect transfer case shift lever to range lever on transfer case.
13. Align and connect propeller shafts.
14. Fill transmission with required lubricant. Check lubricant level in transfer case and add lubricant if necessary.
15. Install transfer case skid plate, if equipped, and crossmember. Tighten attaching bolts/nuts to 41 Nm (30 ft. lbs.).

16. Install exhaust system components.
17. Lower vehicle.
18. Install shift tower and lever assembly. Tighten shift tower bolts to 7 - 10 Nm (5 - 7 ft. lbs.).

19. Install shift lever boot.
20. Install floor console.
21. Connect battery negative cable.