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. Mark propeller shaft and axle yokes for alignment reference. Use paint, scriber, or chalk to mark yokes.
8. Remove propeller shaft.
9. Disconnect and remove exhaust system as necessary.
10. Disconnect wires at backup light switch.
11. Support engine with adjustable safety stand and wood block.
Fig. 6:
12. If transmission is to be disassembled for repair, remove drain bolt at bottom of PTO cover and drain lubricant from transmission (Fig. 6).
13. Remove bolts/nuts attaching transmission to rear mount.
14. Support transmission with a 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.
15. Remove rear crossmember.
16. Remove bolts attaching clutch slave cylinder to clutch housing. Then move cylinder aside for working clearance.
17. Remove wire harness from clips on transmission.
18. Remove bolts attaching transmission clutch housing to the engine block.
19. Slide transmission and jack rearward until input shaft clears clutch disc and pressure plate.
20. Lower transmission jack and remove transmission 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 bottom PTO cover bolt and install bolt in case.
3. Mount transmission on jack and position transmission under vehicle.
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. Fill transmission with recommended lubricant. Correct fill level is bottom edge of fill plug hole.
11. Position transmission harness wires in clips on transmission.
12. Install transmission mount on transmission or rear crossmember.
13. Install rear crossmember.
14. Remove transmission jack and engine support fixture.
15. Align and install propeller shaft.
16. Lower vehicle.
17. Shift transmission into third gear.
18. Clean the mating surfaces of shift tower and isolator plate with suitable wax and grease remover.
19. Apply Mopar Gasket Maker, or equivalent, to the sealing surface of the transmission case. Do not over apply sealant.
20. Install the isolator plate onto the transmission case, metal side down.
21. Install the shift tower onto the isolator plate. No sealant is necessary between the shift tower and top of the isolator plate.
22. Verify that the shift tower, isolator plate, and the shift socket are properly aligned.
23. 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.).
24. Install shift boot and bezel.
25. Connect battery negative cable.