Transmission Replacement

REMOVAL

1. Shift transmission into Neutral, then raise and support vehicle.
2. Remove skid plate, then mark front and rear propeller shafts for installation alignment. Remove propeller shafts.
3. Disconnect transfer case shift linkage from shift lever or range lever.
4. Disconnect wire harness from distance sensor.
5. Remove harness wires from clips on transmission case.
6. Disconnect transmission and transfer case electrical switch. Support transmission with suitable jack and safety chains.
7. Support engine with jack positioned below clutch housing or oil pan flange.
8. Remove bolts attaching rear mount to crossmember. Remove rear crossmember.
9. Remove transfer case attaching nuts, then remove transfer case from transmission.
10. Lower transmission enough to provide access to shift lever.
11. Unseat shift lever dust boot from transmission shift tower. Move boot upward on shift lever for access to lever retainer.
12. Disengage transmission shift lever as follows:
a. Reach around case and press shift lever retainer downward with fingers.
b. Turn retainer counterclockwise to release.
c. Lift lever and retainer out of shift tower.
d. It is not necessary to remove shift lever from floorpan boot. Leave lever in position for later installation.
13. Disconnect and remove engine timing sensor. Remove clutch slave cylinder from clutch housing.
14. Remove bolts attaching clutch housing to engine.
15. Pull transmission rearward until clutch housing is clear of engine. Remove transmission from below vehicle.

INSTALLATION

1. Mount transmission and clutch housing assembly on transmission jack. Secure with safety chains.
2. Lubricate pilot bearing and transmission input shaft splines with Mopar high temperature grease, or equivalent.
3. Align transmission input shaft and clutch disc splines and seat clutch housing on engine.
4. Install and tighten bolts securing clutch housing to engine.
5. Lower transmission sightly for access to shift tower.
6. Reach up and around case and insert shift lever in shift tower. Press lever retainer downward and turn clockwise to lock into position.
7. Install lever dust cover on shift tower.
8. Align transfer case and transmission shafts, then install into transfer case. Tighten transfer case attaching nuts to specifications.
9. Move adjustable support stand from under engine and reposition below transmission. Remove transmission jack.
10. Install rear crossmember. Tighten to specifications.
11. Install slave cylinder in clutch housing. Install engine timing sensor.
12. Connect transfer case electrical wires, shift rod to range lever and vent houses.
13. Connect back-up lamp switch wires and distance sensor.
14. Align and install propeller shafts. Tighten to specifications.
15. Install skid plate and lower vehicle.