G56 Manual Transmission - Installation

INSTALLATION

CAUTION: The release fork is not symmetrical and must be installed with the slots and part number stamping toward the ball stud side. Part number stamping will be right side up when installed correctly. Failure to install the release fork correctly will result in clutch slippage and damage.

1. Clean transmission front housing mounting surface.
2. Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of following components:
- Release fork (1) ball stud (2)
- Release bearing slide surface (3)
- Input shaft splines (4)
- Release bearing bore (5)
- Propeller shaft slip yoke.

3. Support and secure transmission to jack.
4. Raise and align transmission input shaft with clutch disc, then slide transmission into place.
5. Install exhaust bracket diesel engine.
6. Verify front housing is fully seated.
- Diesel Engine: Install transmission bolts (1,2) and tighten to 41 Nm (30 ft. lbs.). Tighten the bolts with washers (2) into the transmission to 68 Nm (50 ft. lbs.).

7. Install crossmember and tighten nuts (2) to 102 Nm (75 ft. lbs.).
8. Install transmission mount bolts (1) and tighten to 68 Nm (50 ft. lbs.).

9. Connect transmission harnesses to clips on case and connect switches.
10. Install slave cylinder and tighten cylinder nuts to 23 Nm (200 in. lbs.).
11. Install transfer case and transfer case linkage 4x4 equipped.
12. Remove transmission jack.

13. Install propeller shaft/shafts with reference marks aligned.

14. Install exhaust pipe. Exhaust Pipe - Installation.
15. Install exhaust bracket (1) and bolts.

16. Remove fill plug (1) on transmission (2) and fill to approximately 16 mm (0.625 inch) from the bottom of the fill hole.
17. Install fill plug and tighten to 57 Nm (42 ft. lbs.).
18. Connect battery negative cable.
19. Install shift lever extension on shift tower and lever assembly.
20. Slide boot down on shift lever extension and install shift boot bezel and screws.
21. Install skid plate, if equipped.