Automatic Transmission Removal / Installation

AUTOMATIC TRANSMISSION REMOVAL / INSTALLATION

Removal

NOTE:If the transmission is to be removed for a period of time, support the engine with a safety stand and a wood block.
1. With the vehicle in neutral, position it on a hoist. See Lifting.

2. If transmission disassembly is required, drain the transmission fluid. See Service and Repair

3. On 4x4 vehicles, remove the transfer case. See .

4. Remove the rear propeller shaft. See Removal and Replacement or Removal and Replacement.

5. Remove the starter motor. See - Service and Repair, or - Service and Repair.

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.
1.




Remove and discard the four torque converter to flexplate nuts.

- Rotate the flexplate to access all the nuts.

4.0L engine

NOTE:Mark the torque converter and the flexplate for proper alignment at installation.
1.




Remove and discard the four torque converter to flexplate nuts.

- Rotate the flexplate to access all the nuts.

All Vehicles

1.




Remove the transmission gear selector lever cable from the manual control lever.

2.




Remove the transmission selector lever cable clip, and remove the cable from the bracket.

3.




Disconnect the transmission wiring harness from the case.
a. Remove the wiring harness from the selector lever cable bracket.

b. Remove the transmission selector lever cable retainer from the case.

4.




Remove the transmission selector lever bracket from the transmission.

5.




Disconnect the transmission electrical connectors.

- Disconnect the transmission connector.
- Disconnect the intermediate shaft speed sensor connector.
- Disconnect the digital transmission range (TR) sensor connector.
- Disconnect the output shaft speed (OSS) sensor connector.

6. Remove the three-way catalytic converter. See - Service and Repair for 2.3L engine, or - Service and Repair for 4.0L engine.

2.3L engine

1.




Remove the rear engine cover plate.

All vehicle.

CAUTION:Care should be taken not to damage the cooler lines.
1.




Disconnect the transmission cooler lines. See Service and Repair.

2.




Remove the transmission mount nuts.

CAUTION:Do not allow the transmission to hang freely.

3.




Position a jack under the transmission.

- Raise and support the transmission.

4x4 vehicles

1.




Remove the crossmember.
a. Remove the 6 bolts (3 each side).

b. Remove the crossmember.

4x2 vehicles

1.




Remove the crossmember.

- Remove the 6 bolts (3 each side).
- Remove the crossmember.

6.




Remove the transmission mount.
a. Remove the transmission mount-to-extension housing bolts.

b. Remove the transmission mount.

7.




If equipped, remove the rear vibration damper.

2.3L engine

1.




Remove the transmission upper fill tube.
a. Remove the bolt.

b. Disconnect the transmission upper fill tube.

2.
NOTE:Lower the jack to gain access to the upper bolts.

3.




Remove the bolts.

4.




Remove the lower screws.

5.




Remove the heated oxygen sensor (HO2S) connector bracket from the transmission.

4.0L engine

1.
NOTE:Lower the jack to gain access to the upper bolts.

2.




Remove the bolts.

All vehicles

1.

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.

2.




Install the SST T979-7902-A or equivalent before lowering the transmission from the vehicle.

3.

WARNING:Secure the transmission to the transmission jack with a safety chain.Lower the transmission.

4. Remove the vent tube assembly.

5. Perform transmission fluid cooler back flushing/cleaning. See Procedures.

Installation

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 SST T979-7902-A or equivalent.

4.0L engine

NOTE:Align the flexplate to converter marks made at removal.
1.




Install the transmission to engine bolts.
a. Install 2 M10 x 40 mm (1.57 in) bolts.

b. Install 4 M10 x 50 mm (1.96 in) bolts.

c. Install 2 M10 x 75 mm (2.95 in) bolts.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.
1.




Install the transmission to engine bolts.
a. Install 1 M10 x 40 mm (1.57 in) bolt.

b. Install 4 M10 x 50 mm (1.96 in) bolts.

c. Install 2 M10 x 75 mm (2.95 in) bolts.Tightening Torque:55 Nm {5.6 kgf-m, 41 ft-lbf}

2.




Install the upper fluid filler tube and bracket bolt.
a. Install the upper filler tube.

b. Install the M10 x 50 mm (1.96 in) bolt.Tightening Torque:55 Nm {5.6 kgf-m, 41 ft-lbf}

3.




Install the lower transmission to engine screws.Tightening Torque:55 Nm {5.6 kgf-m, 41 ft-lbf}

4.




Install the HO2S connector bracket.Tightening Torque:20 Nm {2.0 kgf-m, 15 ft-lbf}

5.




Install the rear engine cover plate.

6. On 4X4 vehicles, install the transfer case. See .

All vehicles

1.




Install the transmission mount.
a. Reposition the exhaust bracket.

b. Install the bolts.Tightening Torque:90 Nm {9.2 kgf-m, 66 ft-lbf}

4x2 vehicles

1.




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

1.




Install the crossmember.
a. Position the crossmember.

b. Install the 6 crossmember bolts (3 each side).Tightening Torque:99 Nm {10.1 kgf-m, 73 ft-lbf}

2.




Install the transmission mount into the crossmember and tighten the transmission mount nuts.

3.




If equipped, install the rear vibration damper.Tightening Torque:30 Nm {3.1 kgf-m, 22 ft-lbf}

4.

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.

5.




Hold the case fitting and install the transmission cooler lines.Tightening Torque:28 Nm {2.9 kgf-m, 21 ft-lbf}

4.0L engine

1.




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.
1.




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

1. Install the starter motor. See - Service and Repair, or - Service and Repair.

2. Install the catalytic converter assembly. See - Service and Repair for 2.3L engine, or - Service and Repair for 4.0L engine.

3.




Install the transmission selector lever bracket and bolts.Tightening Torque:40 Nm {4.1 kgf-m, 30 ft-lbf}

4.




Position the transmission wiring harness in place.
a. Clip harness to the transmission selector lever cable bracket.

b. Clip harness retainer to the case.

5.




Connect the transmission electrical connectors.
a. Connect the transmission connector.

b. Connect the intermediate shaft speed sensor connector.

c. Connect the digital TR sensor connector.

d. Connect the OSS sensor connector.

6.




Move the manual lever into the neutral position.
a. Move the manual lever all the way counterclockwise.

b. Move the manual lever 3 detents clockwise.

7.




Install the transmission selector lever into the bracket and install the clip.

8.




Connect the transmission selector lever cable onto the manual lever and lock the end down.

9. On 4x4 vehicles, install the transfer case. See .

10. Install the rear propeller shaft. See Removal and Replacement or Removal and Replacement.

11. Fill the transmission with fluid and inspect for proper operation. See Automatic Transmission Preliminary Inspection.

12. Verify the transmission selector lever cable is correctly adjusted. See Adjustments.

13. Check the transmission for correct operation.