Removal and Replacement
REMOVAL
1. Remove fan shroud attaching bolts.
2. Disconnect transmission fill tube at upper bracket.
3. Raise vehicle.
4. Remove inspection cover from converter housing and remove skid plate for access, if necessary.
5. Remove transmission fill tube and fill tube O-ring.
6. Remove starter motor.
7. Mark propeller shafts and axle yokes for alignment reference.
8. Disconnect propeller shafts at yokes. Secure shafts to frame rails with wire.
9. Disconnect exhaust pipes at exhaust manifolds, if necessary.
10. Drain transfer case lubricant, if transfer case will also be serviced.
11. Disconnect vehicle speed sensor wires.
12. Disconnect transfer case shift linkage.
13. Disconnect gearshift/tie valve cable and throttle linkage at transmission levers.
14. Disconnect transfer case vent hose. Then disconnect vacuum switch harness.
15. Remove wire harness from clips on transfer case.
16. Remove transfer case attaching nuts and remove transfer case. Use transmission jack or helper to support and remove transfer case.
17. Disconnect park/neutral position switch wires.
18. Disconnect and remove crankshaft position sensor. Retain sensor bolt (or bolts) for reinstallation.
CAUTION: The crankshaft position sensor can be damaged during transmission removal (or installation) if the sensor is still bolted to the engine block. To avoid damage, remove the sensor before removing the transmission.
19. Remove wire harnesses from clips/tie straps on transmission.
20. Remove converter housing access cover and mark drive plate and converter for alignment reference.
21. Remove bolts attaching converter to drive plate.
22. Support engine with support stand.
23. Support transmission with transmission jack. Secure transmission to jack with safety chain.
24. Remove bolts/nuts attaching cushion and torque arm bracket to skid plate.
25. Remove skid plate, or rear crossmember, if equipped.
26. Lower transmission slightly and disconnect cooler lines at transmission.
27. Remove bolts attaching transmission converter housing to engine block.
28. Move transmission and converter rearward until clear of crankshaft.
29. Hold converter in position and lower transmission until converter housing clears engine.
30. Remove converter from transmission.
CAUTION: If the transmission was repaired to correct a problem that generated sludge and debris, the fluid cooler and lines must be reverse flushed and the torque converter and drawback valve replaced. Sludge and metal or friction particles must be removed from the cooler system before reinstalling the transmission. This avoids re-contaminating the repaired transmission. Failure to flush the system will result in repeat failure and a shop comeback.
31. If necessary, following components can now be serviced:
^ Torque Converter
^ Torque Converter Drive plate
^ Oil Pump Seal
^ Engine Rear Core Hole Plugs
^ Engine Rear Oil Galley Plugs
CONVERTER-PUMP SEAL-DRIVE PLATE SERVICE
The drive plate and torque converter can be replaced or removed for service access after the transmission has been removed (Fig. 18).
The torque converter is not a serviceable part. If the converter is contaminated or damaged in any way, it must be replaced as an assembly. Do not attempt to flush a converter contaminated by metal or clutch facing particles. Flushing will not remove these contaminants.
The oil pump seal is accessible and can be replaced after the transmission and torque converter are removed.
Use an externally threaded tool to remove the seal (Fig. 19). To install the seal, use a standard seal driver of the correct size (Fig. 20). Be sure to lubricate the pump seal and converter hub with transmission fluid or petroleum jelly before installation.
INSTALLATION
1. Lubricate converter drive hub and pump seal with MOPAR ATF+4 transmission fluid. Then install converter. Turn converter back and forth to align drive slots in converter hub with pump gear lugs. Be sure converter is fully seated in pump.
2. Temporarily secure converter with C-clamp or metal strap attached across converter housing.
3. Position transmission on jack and secure it with safety chains.
4. Raise transmission and align converter with drive plate.
5. Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.
6. Install two transmission attaching bolts. Tighten bolts just enough to hold transmission converter housing in place on block.
7. Install torque converter attaching bolts. Tighten bolts to following torque.
- 54 Nm (40 ft. lbs.) with 9.5 inch 3-lug converter
- 74 Nm (55 ft. lbs.) with 9.5 inch 4-lug converter
- 74 Nm (55 ft. lbs.) with 10.0 inch 4-lug converter
- 31 Nm (270 inch lbs.) with 10.75 inch 4-lug converter
8. Install and tighten remaining bolts that attach transmission converter housing to engine block. Refer to Fig. 22 for cooler line identification.
CAUTION: Be sure the converter housing is fully seated on the engine block dowels before tightening any bolts.
9. Install crankshaft position sensor.
10. Install transmission fill tube and O-ring.
11. Connect transmission cooler lines to fittings.
12. Install transfer case on transmission. Tighten attaching nuts to 47 Nm (35 ft. lbs.) torque if case has 3/8 studs, or 35 Nm (26 ft. lbs.) if case has 5/16 studs.
13. Install rear crossmember and attach transmission rear support to crossmember.
14. Remove transmission jack.
15. Connect vehicle speed sensor wires.
16. Install inspection cover on converter housing.
17. Install exhaust pipes and support brackets, if removed.
18. Install starter motor.
19. Connect wires to park/neutral position switch.
20. Connect gearshift and linkage and throttle cable.
21. Connect transfer case shift linkage.
22. Connect propeller shafts to transfer case yokes.
23. Connect front exhaust pipes and catalytic converter support bracket bolts (if removed).
24. Install skid plate, rear cushion and bracket, if removed.
25. Fill transfer case to bottom edge of fill plug hole with MOPAR Dexron II.
26. Lower vehicle and fill transmission to correct level with ATF+4, type 9602 fluid.
27. Install fan shroud and bolts (if removed).