Automatic Transmission Removal / Installation
AUTOMATIC TRANSMISSION REMOVAL / INSTALLATIONRemoval Note
Note:
^ If the transmission is to be removed for a period of time, support the engine with a safety stand and a wood block.
Note:
^ When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition.
1. Disconnect the negative battery cable.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. If transmission disassembly is required, drain the transmission fluid.
4. 4X4 Vehicles, remove the transfer case.
5. Remove the propeller shaft.
6. Remove the starter motor.
2.3L engine
Caution:
^ When removing the torque converter nuts, the crankshaft must be rotated only in the clockwise direction, otherwise engine damage can occur. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction between the flange faces on each part. For that reason, the crankshaft sprocket can also be moved when the crankshaft pulley is turned in the counterclockwise direction.
Note:
^ It may be necessary to gain access to the flexplate nuts through the wheel well.
Note:
^ Mark the torque converter and the flexplate for proper alignment at installation.
7. Remove and discard the four torque converter to flexplate nuts.
^ Rotate the flexplate to access all the nuts.
3.0L, and 4.0L, engines
Note:
^ Mark the torque converter and the flexplate for proper alignment at installation.
8. Remove and discard the four torque converter to flexplate nuts.
^ Rotate the flexplate to access all the nuts.
All Vehicles
9. Remove the transmission selector lever cable from the manual control lever.
10. Remove the selector lever cable clip, and remove the cable from the bracket.
11. Disconnect the transmission wiring harness from the case.
(1) Remove the wiring harness from the selector lever cable bracket.
(2) Remove the selector lever cable retainer from the case.
12. Remove the selector lever bracket from the transmission.
13. Disconnect the transmission wiring harness.
^ Disconnect the transmission connector.
^ Disconnect the intermediate shaft speed sensor.
^ Disconnect the digital transmission range (TR) sensor.
^ Disconnect the output shaft speed (OSS) sensor.
14. Remove the three-way catalytic converter.
2.3L engine
15. Remove the rear engine cover plate.
All vehicle.
Caution:
^ Care should be taken not to damage the cooler lines.
16. Disconnect the transmission cooler lines.
17. Remove the transmission mount nuts.
Caution:
^ Do not allow the transmission to hang freely.
18. Position a jack under the transmission.
^ Raise and support the transmission.
4x4 vehicles
19. Remove the crossmember.
(1) Remove the 6 bolts (3 each side).
(2) Remove the crossmember.
4x2 vehicles
20. Remove the crossmember.
^ Remove the 6 bolts (3 each side).
^ Remove the crossmember.
21. Remove the transmission mount.
(1) Remove the transmission mount-to-extension housing bolts.
(2) Remove the transmission mount.
22. If equipped, remove the rear vibration damper.
2.3L engine
23. Remove the transmission upper fill tube.
(1) Remove the bolt.
(2) Disconnect the transmission upper fill tube.
Note:
^ Lower the jack to gain access to the upper bolts.
25. Remove the bolts.
26. Remove the lower screws.
27. Remove the H02S connector bracket from the transmission.
3.0L engine
28. Remove the transmission upper fill tube.
(1) Remove the bolt.
(2) Disconnect the transmission upper fill tube.
Note:
^ Lower the jack to gain access to the upper bolts.
30. Remove the bolts.
4.0L engine
Note:
^ Lower the jack to gain access to the upper bolts.
32. Remove the bolts.
All vehicles
Warning:
^ The torque converter is heavy and may result in injury if it falls out of the transmission. Secure the torque converter in the transmission.
34. Install the torque converter holding tool SST (T979-7902-A) or equivalent before lowering the transmission from the vehicle.
Warning:
^ Secure the transmission to the transmission jack with a safety chain.
35. Lower the transmission.
36. Remove the vent tube assembly.
37. Perform transmission fluid cooler back flushing/cleaning.
Installation Note
1. Install the vent tube assembly.
Warning:
^ Secure the transmission to the transmission jack with a safety chain.
2. Raise and position the transmission.
3. Remove the torque converter holding tool SST.
4.0L engine
Note:
^ Align the flexplate to converter marks made at removal.
4. Install the transmission to engine bolts.
(1) Install 2 M10 x 40 mm (1.57 in) bolts.
(2) Install 4 M10 x 50 mm (1.96 in) bolts.
(3) Install 2 M10 x 75 mm (2.95 in) bolts.
Tightening Torque:
55 Nm (5.6 kgf-m, 41 ft-lbf)
3.0L engine
Note:
^ Align the flexplate to converter marks made at removal.
5. Install the transmission to engine bolts.
(1) Install 1 M10 x 40 mm (1.57 in) bolt.
(2) Install 2 M10 x 50 mm (1.96 in) bolts.
(3) Install 2 M10 x 75 mm (2.95 in) bolts.
6. Install the upper fluid filler tube and bracket bolt.
(1) Install the upper filler tube.
(2) Install the M10 x 50 mm (1.96 in) bolt.
Tightening Torque:
55 Nm (5.6 kgf-m, 41 ft-lbf)
2.3L engine
Note:
^ Align the flexplate to the converter marks made at removal.
7. Install the transmission to engine bolts.
(1) Install 1 M10 x 40 mm (1.57 in) bolt.
(2) Install 4 M10 x 50 mm (1.96 in) bolts.
(3) Install 2 M10 x 75 mm (2.95 in) bolts.
8. Install the upper fluid filler tube and bracket bolt.
(1) Install the upper filler tube.
(2) Install the M10 x 50 mm (1.96 in) bolt.
9. Install the lower transmission to engine screws.
Tightening Torque:
55 Nm (5.6 kgf-m, 41 ft-lbf)
10. Install the HO2S connector bracket.
11. Install the rear engine cover plate
12. On 4X4 vehicles, install the transfer case.
All vehicles
13. Install the transmission mount.
(1) Reposition the exhaust bracket.
(2) Install the bolts.
Tightening Torque:
90 Nm (9.2 kgf-m, 66 ft-lbf)
4x2 vehicles
14. Install the crossmember.
^ Position the crossmember.
^ Install the 6 crossmember bolts (3 each side).
Tightening Torque:
99 Nm (10.1 kgf-m, 73 ft-lbf)
4x4 vehicles
15. Install the crossmember.
(1) Position the crossmember.
(2) Install the 6 crossmember bolts (3 each side).
16. Install the transmission mount into the crossmember and tighten the transmission mount nuts.
17. If equipped, install the rear vibration damper.
Tightening Torque:
30 Nm (3.1 kgf-m, 22 ft-lbf)
Caution:
^ Use care not to bend or otherwise damage the cooler lines.
Note:
^ Prior to installing the cooler lines to the case, inspect the O-ring seals. If damaged, new O-ring seals must be installed.
19. Hold the case fitting and Install the transmission cooler lines.
Tightening Torque:
28 Nm (2.9 kgf-m, 21 ft-lbf)
3.0L and 4.0L, engines
20. Install four new torque converter to flywheel nuts.
Tightening Torque:
35 Nm (3.6 kgf-m, 26 ft-lbf)
^ Rotate the crankshaft as needed to gain access to all the flywheel nuts.
2.3L vehicles
Caution:
^ When installing the torque converter nuts, the crankshaft must be rotated only in the clockwise direction, otherwise engine damage can occur. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction between the flange faces on each part. For that reason, the crankshaft sprocket can also be moved when the crankshaft pulley is turned in the counterclockwise direction.
21. Install 4 new torque converter nuts.
^ Rotate the crankshaft as needed to gain access to all the nuts.
Tightening Torque:
35 Nm (3.6 kgf-m, 26 ft-lbf)
All vehicles
22. Install the starter, motor.
23. Install the catalytic: converter assembly.
24. Install the selector lever bracket and bolts.
25. Position the transmission wiring harness in place.
(1) Clip harness to the selector lever cable bracket.
(2) Clip harness retainer to the case.
26. Connect the transmission wiring harness.
(1) Connect the transmission connector.
(2) Connect the intermediate shaft speed sensor.
(3) Connect the digital transmission range (TR) sensor connector.
(4) Connect the output shaft speed (OSS) sensor.
27. Move the manual lever into the NEUTRAL position.
(1) Move the manual lever all the way counterclockwise.
(2) Move the manual lever 3 detents clockwise.
28. Install the selector lever into the bracket and install the clip.
29. Connect the selector lever cable onto the manual lever and lock the end down.
Note:
^ Align the driveshaft yoke and the axle shaft marks made at removal to maintain driveline balance.
31. Align and install the rear propeller shaft.
32. Lower the vehicle.
Note:
^ When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition.
33. Connect the negative battery cable.
34. Fill the transmission with fluid and inspect for proper operation.
35. Verify that the selector lever cable is correctly adjusted.
36. Check the transmission for correct operation.