Installation

INSTALLATION
1. Install clutch housing on transmission and tighten housing bolts to 46 Nm (34 ft. lbs.) (Fig. 7).
2. Lubricate contact surfaces of release fork pivot ball stud and release fork with high temp grease.
3. Install release bearing, fork, and retainer clip.
4. Position and secure transmission on transmission jack.
5. Lightly lubricate pilot bearing and transmission input shaft splines with Mopar high temp grease.
6. Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place.

NOTE: Verify housing is seated on engine block before tightening bolts.

7. Install and tighten clutch housing-to-engine bolts:
- 3/8 inch bolts: 37 Nm (27 ft. lbs.)
- 7/16 inch bolts: 58 Nm (43 ft. lbs.)
- M12 bolts: 75 Nm (55 ft. lbs.)

8. Install clutch housing brace rod.
9. Lower transmission approximately 7 - 8 cm (3 in.) for access to shift tower. Put transmission in first or third gear.
10. Reach up and around transmission and insert shift lever in shift tower. Press lever retainer downward and turn it clockwise to lock it in place. Then install lever dust boot on shift tower.
11. Install fasteners to hold rear cushion and bracket to transmission. Then tighten bolts/nuts to 54 Nm (40 ft. lbs.).
12. Install rear crossmember and tighten crossmember-to-frame bolts to 41 Nm (31 ft. lbs.).
13. Remove support stands from engine and transmission.
14. Install and connect crankshaft position sensor.
15. Position transfer case on transmission jack.
16. Secure transfer case to jack with safety chains.
17. Raise transfer case and align transfer case input shaft to the transmission output shaft.
18. Slide transfer case forward until case is seated on transmission.
19. Install nuts to attach transfer case to transmission and tighten to 35 Nm (26 ft. lbs.).
20. Connect transfer case shift linkage at transfer case.
21. Connect transfer case vent hose.
22. Secure wire harnesses in clips/tie straps on transmission and transfer case.
23. Engage wire connectors attached to all necessary transmission or transfer case components.
24. Install rear propeller shaft slip yoke to transmission or transfer case output shaft.





25. Install front and rear propeller shafts with reference marks aligned (Fig. 94).
26. Install slave cylinder in clutch housing.
27. Install skid plate if equipped.
28. Fill transmission and transfer case with fluid.
29. Lower vehicle.