Installation

INSTALLATION

1. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. Verify that the converter hub o-ring is properly installed and is free of any debris. The hub must be smooth to avoid damaging pump seal at installation.
2. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
3. Lubricate oil pump seal lip with transmission fluid.
4. Align converter and oil pump.
5. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
6. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13 mm (1/2 in.) to rear of straightedge when converter is fully seated.
7. Temporarily secure converter with C-clamp.










8. Position transmission on jack and secure it with chains.
9. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
10. Apply a light coating of Mopar(R) High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
11. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.

NOTE: Before aligning the transmission to the engine block fit the transmission fill tube to the vehicle.

12. Move transmission forward. Then raise, lower, or tilt transmission (2) to align the converter housing with the engine (1) block dowels.
13. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.










14. Install two bolts (3) to attach the transmission (2) to the engine (1).
15. Install remaining torque converter housing to engine bolts. Tighten to 68 Nm (50 ft.lbs.).










16. Install both the left and right side oil pan to transmission bolts (1), 5.7L only. Torque the bolts to 54 Nm (40 ft. lbs.).










17. Connect cooler lines (2) to transmission (1).










18. Install transmission fill tube (2) to the transmission (1).










19. Install rear transmission crossmember. Tighten crossmember to frame bolts to 68 Nm (50 ft.lbs.).
20. Install rear support to transmission. Tighten bolts to 47 Nm (35 ft.lbs.).
21. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 Nm (35 ft.lbs.). Tighten the clevis bracket to rear support bolt to 68 Nm (50 ft.lbs.).
22. Remove engine support fixture.
23. Install new plastic retainer grommet on any shift cable that was disconnected. Grommets should not be reused. Use pry tool to remove rod from grommet and cut away old grommet. Use pliers to snap new grommet into cable and to snap grommet onto lever.
24. Connect gearshift cable (3) to the shift cable bracket (4) and the transmission manual lever (2).










25. Connect wires to the input speed sensor (2). Be sure transmission harnesses are properly routed.










26. Connect wires to the output speed sensor (2). Be sure transmission harnesses are properly routed.










27. Connect wires to the transmission solenoid/TRS assembly (2). Be sure transmission harnesses are properly routed.










28. Connect wires to the line pressure sensor (2). Be sure transmission harnesses are properly routed.










CAUTION: It is essential that the correct length bolts are used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

29. Install all torque converter-to-driveplate bolts (3) by hand.
30. Verify that the torque converter is pulled flush to the driveplate. Tighten bolts to 31 Nm (270 in. lbs.).










31. Install the structural cover (1), 5.7L shown. Structural Dust Cover - Installation










32. If necessary, install the NV140 transfer case (1)..










33. If necessary, install the NV245 transfer case (1)..

34. Install starter motor. Starter - Installation
35. Install exhaust components.
36. Align and connect propeller shaft(s). Drive Shaft - Installation
37. Adjust gearshift cable if necessary. Adjustments
38. Lower vehicle.
39. Fill transmission with appropriate fluid.