Installation

Installation

All vehicles

1. CAUTION: Prior to the installation of the transmission the fluid, cooler lines and the cooler bypass valve must be cleaned. Otherwise transmission failure can occur.

CAUTION: A new transmission Oil-To-Air (OTA) cooler must be installed if the transmission was overhauled or exchanged due to a failure of the transmission. Otherwise transmission failure can occur.

Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or install new as required.





2. CAUTION: Prior to the installation of the assembly, the torque converter pilot hub must be correctly lubricated or damage to the torque converter or the engine crankshaft can occur.

Lubricate the torque converter pilot hub with multi-purpose grease.





3. Raise the transmission into place.





4. CAUTION: Do not use the cooler bypass valve as a handle. Damage to the cooler bypass valve assembly may occur or damage to the case may result.

CAUTION: Be careful not to raise the transmission up too far. The sensors may make contact with the underbody of the vehicle and cause damage to the sensors. Sensor failure or leakage may occur.

NOTE: While raising the transmission up into the engine compartment, make sure to align the fluid filler tube with the stub tube on the transmission with dipstick as a guide

Position the transmission.





5. CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear. Use care not to damage the flexplate and the converter pilot. The torque converter must rest squarely against the flexplate, indicating the converter pilot is not binding in the crankshaft.

NOTE: Gasoline engine shown, diesel engine similar

While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.





Gasoline engines
6. Install seven transmission-to-engine bolts.





7. Install the new torque converter-to-flexplate nuts.





8. Install the cylinder block opening cover.





9. Install the flexplate inspection cover and bolts.





Diesel engines
10. Install six transmission-to-engine bolts.





11. Install new torque converter retaining nuts.





12. Install the flexplate inspection cover bolts.
1 Install the flexplate inspection cover.
2 Install the flexplate inspection cover bolts.
13. Install the starter motor.

Gasoline engines
14. Install the starter motor.





All vehicles
15. Connect the solenoid pack electrical connector.





16. Connect the Digital Transmission (TR) sensor connector.





17. Connect the shift cable.
1 Install the cable housing bracket.
2 Install the shift cable to the manual lever.





18. Connect the Turbine Shaft Speed (TSS) sensor and the Output Shaft Speed (OSS) sensor.





19. NOTE: If the transmission fluid cooler tubes or the cooler bypass valve have not been flushed, it is necessary to do so at this time. Replace the oil-to-air cooler.

Install the transmission fluid cooler tubes to the cooler bypass valve.
20. If equipped, install the power take-off unit (PTO).

4x4 vehicles
21. Install the transfer case.





4x2 vehicles
22. Install the transmission mount.





23. Install the crossmember to the transmission mount, using one nut to hold crossmember in place. Raise the transmission and align the crossmember bolt holes.





24. Install the bolts.





25. Install the bolts.
26. Remove the high-lift transmission jack.





27. Install the remaining nut. Tighten the nuts.
28. Install the rear driveshaft.

Vehicles equipped with a transmission mounted parking brake
29. Install the transmission mounted parking brake.





4x2 vehicles
30. Reconnect the wire harness to the frame.

All vehicles
31. Backflush the cooler lines before installing a new filter, filter kit or connecting the cooler lines to the transmission. Do not flush the Oil To Air (OTA) cooler. Install a new OTA.
32. Once the system has been cleaned, carry out the fluid cooler flow test to assure that the system has the correct amount of fluid flow. Reconnect all cooler lines.





33. NOTE: If the vehicle was not equipped with a fluid filter, install a fluid filter service kit (XC3Z-7B155-AA) following the instructions supplied in the kit. If the vehicle was equipped with a fluid filter, install a new filter (XC3Z-7B1 55-BA).

Install a new inline transmission fluid filter kit or filter.
34. Lower the vehicle.

35. NOTE: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair, the strategy parameters stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If a concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis.

The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.
Connect the battery ground cable.
36. Fill to correct level with clean automatic transmission fluid.