G56 Manual Transmission - Installation

INSTALLATION







1. Clean transmission front housing mounting surface.
2. Apply light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of following components:
- release fork (1) ball stud (2)
- release bearing slide surface (3)
- input shaft splines (4)
- release bearing bore (5)
- propeller shaft slip yoke.







3. Support and secure transmission to jack.
4. Raise and align transmission input shaft with clutch disc, then slide transmission into place.
5. Install exhaust bracket diesel engine.
6. Verify front housing is fully seated.
- Diesel Engine: Install transmission bolts (1 2) and tighten to 41 N-m (30 ft. lbs.). Tighten the bolts with washers (2) into the transmission to 68 N-m (50 ft. lbs.).
- 5.7L Engine: Install transmission top four 3/8 bolts and tighten to 41 N-m (30 ft. lbs.).

CAUTION: 5.7 L transmission bolts must be installed in the following order. Failure to follow these instructions will stress the engine and transmission.







7. Install 5.7 L front dust shield bolts (3) and tighten to 54 N-m (40 ft. lbs.). On 5.7L if structural dust cover was removed, install onto the transmission and engine.
8. Install structural dust cover (1) 7/16 bolts (2) and tighten to 68 N-m (50 ft. lbs.).
9. Install exhaust Y-pipe 5.7L engine.







10. Install crossmember and tighten nuts (2) to 102 N-m (75 ft. lbs.).
11. Install transmission mount bolts (1) and tighten to 68 N-m (50 ft. lbs.).







12. Install starter motor (1) 5.7L.
13. Connect transmission harnesses to clips on case and connect switches.







CAUTION: Do not allow release lever plunger to pivot more than 20 in either direction in the slave cylinder bore. Allowing the plunger to pivot more than 20 in the bore will cause fluid to bypass the seal and result in fluid leakage.

NOTE: Pull the clutch release lever toward the slave cylinder opening to insure proper seating of the slave cylinder plunger to the release lever pocket.

14. Install slave cylinder and tighten cylinder nuts to 23 N-m (200 in. lbs.).
15. Install transfer case and transfer case linkage 4x4 equipped.
16. Remove transmission jack.







17. Install propeller shaft/shafts with reference marks aligned.
18. Install exhaust on the exhaust manifolds.







19. Remove fill plug (1) on transmission (2) and fill to bottom edge of fill plug hole.
20. Install fill plug and tighten to 57 N-m (42 ft. lbs.).
21. Connect battery negative cable.
22. Install shift lever extension on shift tower and lever assembly.
23. Slide boot down on shift lever extension and install shift boot bezel and screws.
24. Install skid plate, if equipped.