4WD
REMOVAL1. Disconnect battery negative cable.
2. Shift transmission into Neutral.
3. Remove screws attaching shift boot bezel and slide boot upward on shift lever extension.
4. Remove shift lever extension as follows:
a. Obtain Remover/Installer Tool 6783, or equivalent.
b. Scribe mark position of extension on shank of shift lever.
c. Position notched, lower end of tool just under square shank of shift lever.
d. Position tool upper jaws under flange on shift lever extension.
e. Tighten tool screw to pull extension off square shank of shift lever.
f. Remove lever extension and tool.
5. Remove bolts attaching shift tower and lever assembly to rear case. Then remove shift tower and lever as an assembly.
6. Remove crankshaft position sensor. Retain sensor attaching bolts.
7. Raise vehicle on hoist.
8. Remove skid plate, if equipped.
9. Drain transmission lubricant if transmission will be disassembled for service.
10. Mark propeller shafts and U-joints for installation reference. Then disconnect and remove propeller shafts.
11. Disconnect vehicle speed sensor wires.
12. Disconnect transfer case shift linkage at transfer case range lever.
13. Remove bolts attaching shift linkage bracket to transfer case and move linkage and bracket aside.
14. Support transfer case with transmission jack.
15. Remove nuts attaching transfer case to transmission adapter housing.
16. Remove transfer case with aid of helper.
17. Support engine with adjustable jack stand.
18. Remove nuts and bolts attaching support bracket and cushions to fixed crossmember.
19. Remove nuts and bolts attaching removable crossmember to frame rails.
20. Remove crossmember.
21. Disconnect exhaust as necessary.
22. Remove slave cylinder attaching nuts and remove cylinder from clutch housing. Move cylinder aside for working clearance.
23. Remove clutch housing dust cover.
24. On some models, it may be necessary to remove front axle struts and oil filter for access and removal clearance. Remove these components if necessary.
25. Support transmission with transmission jack. Secure transmission to jack with safety chains.
26. Remove bolts attaching transmission clutch housing to engine block.
27. Move transmission rearward until transmission input shaft is clear of clutch disc and cover. Then lower jack and remove transmission from under vehicle.
INSTALLATION
1. Make sure transmission front housing and engine block contact surfaces are clean.
2. Apply light coat of MOPAR high temperature bearing grease to contact surfaces of following components:
- input shaft splines and pilot bearing hub.
- release bearing slide surface of front retainer.
- pilot bearing.
- release bearing bore.
- release fork.
- release ball stud.
- propeller shaft slip yoke.
3. Mount transmission on jack. Secure transmission to jack with safety chains.
4. Align transmission input shaft with clutch disc. Then slide clutch housing into place on engine block.
5. Install and tighten transmission attaching bolts to 54 - 61 Nm (40 - 45 ft. lbs.) torque. Be sure housing is fully seated before tightening bolts. If equipped, install dust cover after tightening housing bolts.
6. Fill transmission with MOPAR lubricant. Correct fill level is to bottom edge of fill plug hole.
7. Connect backup lamp switch wires.
8. Connect transmission harnesses and vent line to retainer clips on housing.
9. Install center crossmember. Tighten crossmember-to-frame bolts to 67 Nm (50 ft. lbs.) torque.
10. Tighten crossmember-to-support bracket nuts to 54 - 61 Nm (40 - 45 ft. lbs.) torque.
11. Install slave cylinder in transmission clutch housing. Tighten cylinder attaching nuts to 23 Nm (200 inch lbs.) torque.
12. Remove jack used to support transmission.
13. Install strut bolts/nuts, if removed.
14. Install transfer case. Align and position transfer case with transmission jack or aid of helper.
15. Install and tighten transfer case attaching nuts to 47 Nm (35 ft. lbs.) torque.
16. Install and connect transfer case shift linkage.
17. Connect vehicle speed sensor harness wire to sensor.
18. Align and connect exhaust system components. Be sure exhaust components are clear of all chassis and driveline components.
19. Align and install front and rear propeller shafts. Tighten U-joint clamp bolts to 19 Nm (170 inch lbs.) torque.
20. Verify that all linkage components, hoses and electrical wires have been connected.
21. Check transfer case fluid level. Add MOPAR Dexron II, or ATF Plus if necessary. Correct level is to edge of fill plug hole. Be sure transfer case is level before checking or adding fluid.
22. Check and adjust transfer case shift linkage if necessary.
23. Install transfer case skid plate, if equipped.
24. Install crankshaft position sensor.
25. Remove any remaining support stands and lower vehicle.
26. Connect battery negative cable.
27. Install shift tower and lever assembly. Tighten shift tower bolts to 7 - 10 Nm (5 - 7 ft. lbs.) torque.
28. Install shift lever extension with Tool 6783, or equivalent as follows:
a. Reposition upper jaw of Remover/Installer Tool 6783, or equivalent above flange on lever extension. Tool will now be used to press extension back onto shift lever.
b. Tighten tool screw to press extension back onto lever. Press extension to scribe mark made during removal.
c. Remove special tool.
29. Install shift boot and bezel.