Installation

INSTALLATION

NOTE: Check the transmission damper 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 the pump seal at installation.





1. Lubricate the fluid pump seal lip with transmission fluid.
2. Align the transmission damper to the fluid pump.
3. Carefully insert the transmission damper into the fluid pump. Rotate the transmission damper back and forth until it is fully seated in the pump gears.
4. Check the transmission damper seating with Gauge Bar 6311 (1) and a straightedge (2). The surface of damper should be at least 26mm (1.02 in.) to the straightedge when the damper is fully seated.
5. Hold the transmission damper in place during transmission installation
6. Position the transmission on a transmission jack and secure it with chains.
7. Check the condition of the flexplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in the engine block and protrude far enough to hold the transmission in alignment.
8. Apply a light coating of Mopar(R) High Temp Grease to the transmission damper hub pocket in the rear pocket of the engine crankshaft.
9. Position the RH catalytic converter and hang with mechanics wire.
10. Raise the transmission and align the transmission damper with the flexplate and the transmission bell housing with the engine block.





11. Position the high voltage cable assembly (2) and install the bolts (1). tighten the bolts to 11 Nm ( 97 in. lbs.).





12. Install the cable insulator (1) and bolt (2) and tighten the insulator bolt to 11 Nm ( 97 in. lbs.).





13. Install the high voltage cable to electric motor access cover (2).Tighten the bolts (1) to 11 Nm ( 97 in. lbs.).





14. Install the high voltage cable bracket bolts (1) to the transmission (2) Tighten to 11 Nm ( 97 in. lbs.).
15. Position the RH catalytic converter. Do not install at this time.





16. Move the transmission (1) forward then raise lower, or tilt the transmission to align the converter housing with the engine (2) block dowels.
17. Carefully work the transmission (1) forward and over the engine block dowels until the damper hub is seated in crankshaft. Verify that no wires, or the transmission vent hose have become trapped between the engine block and the transmission.
18. Install the two bell housing bolts to attach the transmission to the engine.
19. Install the remaining transmission bell housing to engine bolts. Tighten the lower 4 bolts to 54 Nm (40 ft. lbs.) and the upper 4 bolts to 41 Nm ( 30 ft. lbs.).





20. Connect the RH side transmission connectors (1) to the transmission (2).





21. Position the transmission heat shield (2) to the transmission. Install the bolts and tighten the 2 bolts and the pinch bolt (1) to 11 Nm (97 in. lbs.).






CAUTION: It is essential that the correct length bolts be used to attach the transmission damper to the flexplate. Bolts that are too long will cause damage to the transmission.

22. Rotate the crankshaft in a clockwise direction, until the transmission damper to the flex plate bolts can be installed. Install the transmission damper to the flexplate bolts one at a time and tighten to 31 Nm (23 ft. lbs.). Rotate the crankshaft with a socket wrench on the harmonic balancer.





23. Install the engine structural dust cover (2). Structural Dust Cover - Installation.





24. Connect the transmission cooler lines (1) to the fittings at the transmission (2).





25. Position the steering rack (7) back and install the bolts (4,6). Tighten the bolts to 258 Nm (190 ft. lbs.).





26. Install the gearshift cable (1) to the shift cable support bracket (2).
27. Connect the gearshift cable (1) to the support bracket (2) and the transmission manual lever (3).
28. Install the RH catalytic converter oxygen sensors. Installation.





29. Mount the transfer case on a transmission jack.
30. Secure the transfer case to the jack with chains.
31. Position the transfer case under the vehicle.
32. Align the transfer case (2) and the transmission shafts.Install the transfer case (2) onto the transmission (1).
33. Install and tighten the transfer case attaching nuts to 40 Nm (30 ft. lbs.).





34. Install the exhaust hanger (2) to the transfer case. Install the bolts (1) and tighten to 23 Nm (17 ft. lbs.).





35. Route the transmission harness and make all necessary connections.
36. Connect the transfer case shift motor (1) and the encoder (2).





37. Install the clevis bracket (2) and bolts (1). Tighten to 54 Nm (40 ft. lbs.).





38. Install the transmission mount (2) and bolts (1). Tighten to 68 Nm (50 ft. lbs.).





39. Install the rear transmission crossmember (3). Tighten the crossmember to the frame bolts (1) to 68 Nm (50 ft.lbs.) and the crossmember to the transmission mount nuts (2) to 54 Nm (40 ft. lbs.).





40. Install the transmission auxiliary control pump (2) bolts (1) then Tighten bolts to 11 Nm (97 in. lbs.).





41. Install the bolt (1) attaching the auxiliary control pump harness (2) to the transmission bellhousing (3). Tighten the bolt to 11 Nm (97 in. lbs.).
42. Connect the auxiliary control pump electrical connector.





43. Position the fuel line (2) back and install the fuel line bolt (1). Tighten the bolt to 11 Nm (97 in. lbs.).





44. Connect the transfer case vent hose to the transfer case.
45. Install the rear propeller shaft. Drive Shaft - Installation.

NOTE: Do not fully install the front propeller shaft at this time.

46. Position the front propeller shaft.





47. Install the LH catalytic converter.
48. Install the LH catalytic converter to the exhaust manifold retainers. Tighten the nuts to 34 Nm (25 ft. lbs.).
49. Connect the LH catalytic converter (1) to the RH catalytic converter (2). Install the clamp (3) and tighten to 42 Nm (31 ft. lbs).
50. Install the LH catalytic converter oxygen sensors. Installation.





51. Install the RH catalytic converter (1) to the exhaust manifold bolts (2). Tighten the nuts to 34 Nm (25 ft. lbs.).
52. Install the front propeller shaft. Drive Shaft - Installation.





53. Install the muffler and tailpipe assembly (3) to the exhaust hangers (2).
54. Install the muffler and tailpipe assembly (3) from the y-pipe assembly (4) by installing the clamp (1). Tighten the clamp to 61 Nm (45 ft. lbs.).
55. Perform the High Voltage System Power Up. Battery System - High Voltage Power Up
56. Adjust the gearshift cable if necessary.Adjustments.
57. Check and adjust the transfer case fluid.
58. Check the transmission fluid level. Adjust the fluid level with DEXRON(R) VI, Automatic Transmission Fluid. . Fluid Level Check
59. Lower and remove the vehicle support.