NV5600 - Manual Transmission
REMOVAL1. Disconnect battery negative cable.
2. Shift transmission into Neutral.
3. Remove screws attaching shift boot to floorpan. Then slide boot upward on the shift lever.
4. Remove the bolts holding the shift tower to the isolator plate and transmission gear case.
5. Remove the shift tower and isolator plate from the transmission gear case.
6. Raise and support vehicle.
7. Remove skid plate, if equipped.
Fig. 7:
8. If transmission will be disassembled for repair, remove drain bolt at bottom of PTO cover and drain lubricant from transmission (Fig. 7).
9. Mark propeller shafts and yokes for assembly reference.
10. Disconnect propeller shafts and remove propeller shafts.
11. Disconnect and remove exhaust system Y-pipe. Then disconnect and lower remaining exhaust pipes for clearance as necessary.
12. Support engine with adjustable safety stand.
13. Disconnect backup lamp switch wires.
14. Disconnect transfer case shift linkage at transfer case range lever.
15. Support transfer case with transmission jack. Secure transfer case to jack with safety chains.
16. Remove transfer case attaching nuts.
17. Move transfer case rearward until input gear clears transmission mainshaft.
18. Lower transfer case assembly and move it from under vehicle.
19. Support transmission with transmission jack. Secure transmission to jack with safety chains.
NOTE: It is recommended that a heavy duty, scissors style transmission jack be used to remove and install the NV5600 transmission.
20. Remove transmission harness from retaining clips on transmission.
21. Remove bolts/nuts attaching transmission mount to rear crossmember.
22. Remove rear crossmember.
23. Remove clutch slave cylinder splash shield, if equipped.
24. Remove bolts attaching clutch slave cylinder to the clutch housing. Then move the slave cylinder aside for working clearance.
25. Remove bolts attaching transmission clutch housing to engine block.
26. Move transmission rearward until input shaft clears clutch disc.
27. Lower transmission and remove it from under vehicle.
INSTALLATION
NOTE: If a new transmission is being installed, be sure to use all components supplied with the new transmission. For example, if a new shift tower is supplied with the new transmission, do not re-use the original shift tower.
1. Apply light coat of Mopar high temperature bearing grease to contact surfaces of following components: input shaft splines. release bearing slide surface of front retainer. release bearing bore. release fork. release fork ball stud. propeller shaft slip yoke.
2. Apply sealer to threads of PTO cover bottom drain bolt then install bolt in case.
3. Mount transmission on jack and position transmission under vehicle. Secure transmission to jack with safety chains.
NOTE: It is recommended that a heavy duty, scissors style transmission jack be used to remove and install the NV5600 transmission.
4. Raise transmission until input shaft is centered in clutch disc hub.
5. Move transmission forward and start input shaft in clutch disc and pilot bushing/bearing.
6. Work transmission forward until seated against engine block. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
7. Install and tighten transmission-to-engine block bolts.
8. Install clutch slave cylinder.
9. Connect backup light switch wires.
10. Position transmission harness wires in clips on transmission.
11. Install transmission mount on transmission or rear crossmember.
12. Install rear crossmember.
13. Remove transmission jack and engine support fixture.
14. Install transfer case on transmission jack. Secure transfer case to jack with safety chains.
15. Raise jack and align transfer case input gear with transmission mainshaft.
16. Move transfer case forward and seat it on adapter.
17. Install and tighten transfer case attaching nuts. Tighten nuts to 41 - 47 Nm (30 - 35 ft. lbs.) if case has 3/8 studs, or 30 - 41 Nm (22 - 30 ft. lbs.) if case has 5/16 studs.
18. Connect transfer case shift lever to range lever on transfer case.
19. Align and connect propeller shafts.
20. Fill transmission with required lubricant. Check lubricant level in transfer case and add lubricant if necessary.
21. Install transfer case skid plate, if equipped, and crossmember. Tighten attaching bolts/nuts to 41 Nm (30 ft. lbs.) torque.
22. Install exhaust system components.
23. Lower vehicle.
24. Shift transmission into third gear.
25. Clean the mating surfaces of shift tower, isolator plate, and transmission case with suitable wax and grease remover.
26. Apply Mopar Gasket Maker, or equivalent, to the sealing surface of the transmission case. Do not over apply sealant.
27. Install the isolator plate onto the transmission case, metal side down.
28. Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and top of the isolator plate.
29. Verify that the shift tower, isolator plate, and the shift tower bushings are properly aligned.
30. Install the bolts to hold the shift tower to the isolator plate and the transmission case. Tighten the shift tower bolts to 10.2 - 11.25 Nm (7.5 - 8.3 ft. lbs.).
31. Install shift lever boot and bezel.
32. Connect battery negative cable.