Installation
INSTALLATION1. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation.
2. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
3. Lubricate oil pump seal lip with transmission fluid.
4. Place torque converter (1) in position in transmission (2).
CAUTION: Do not damage oil pump seal or converter hub while inserting torque converter into the front of the transmission.
5. Align torque converter to oil pump seal opening.
6. Insert torque converter hub into oil pump.
7. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears.
8. Check converter seating with a scale and straightedge (A). Surface of converter lugs should be at least 19 mm (3/4 inch) to rear of straightedge when converter is fully seated.
9. If necessary, temporarily secure converter with C-clamp attached to the converter housing.
10. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
11. Apply a light coating of Mopar High Temp Grease to the torque converter hub pocket in the rear pocket of the engines crankshaft.
12. Raise transmission (3) and align the torque converter with the drive plate and the transmission converter housing with the engine block (1).
13. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
14. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
15. Install two bolts (2) to attach the transmission to the engine.
16. Install remaining torque converter housing to engine bolts (2). Tighten to 39 Nm (29 ft. lbs.).
17. Install rear transmission crossmember (1). Tighten crossmember to frame bolts to 68 Nm (50 ft. lbs.).
18. Install rear support (3) to transmission. Tighten bolts to 47 Nm (35 ft. lbs.).
19. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts(2) to 47 Nm (39 ft. lbs.).
20. Remove engine support fixture.
21. Install the transmission (3) to engine oil pan (2) bolts (1). Tighten to 39 Nm (29 ft. lbs.).
22. Connect input (1) and output (2) speed sensor wires and the transmission range sensor (3).
23. Connect wires to the solenoid/pressure switch assembly (1).
24. Install the crankshaft position sensor.
25. Connect the gearshift cable (1) to the transmission manual shift lever (3).
CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.
26. Install all torque converter-to-driveplate bolts (1) by hand.
27. Verify that the torque converter is pulled flush to the driveplate. Tighten bolts to 42 Nm (30.5 ft. lbs.).
28. Install the torque converter bolt access cover (1) onto the transmission, for vehicles equipped with 3.5L engines. Install the access cover bolt (2) and tighten to 11 Nm (8 ft. lbs.).
29. Install the structural collar (2) and bolts (3, 4) for vehicles equipped with a 2.7L engine.
30. Install starter motor (1).
31. Connect the cooler line fittings (2) and cooler lines (1) to the transmission.
NOTE: Inspect the fill tube grommet to determine if the grommet is new or used. If a new fill tube grommet is in the transmission case, pierce the center of the grommet with a ballpoint pen, or similar instrument, to prepare the grommet for the fill tube installation.
32. Install the transmission fill tube (2).
33. Install exhaust components.
34. Align and connect the propeller shaft (1).
35. Adjust gearshift cable if necessary.
36. Lower vehicle.
37. Connect negative battery cable.
38. Fill transmission with appropriate transmission fluid.
39. Verify proper operation.