Installation

INSTALLATION

NOTE: After the installation of the transmission, a quick learn must be performed using the scan tool. AS68RC Transmission










NOTE: If the torque converter hub is severely scored or gouged it must be replaced.

1. 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 trans jell or petroleum jelly.
4. Align converter and oil pump.
5. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
6. Check converter seating with steel scale (1) and straightedge (2). Surface of converter lugs should be at least 28.2 mm (1.12 in.) to rear of straightedge when converter is fully seated.
7. Temporarily secure converter with C-clamp.










8. Position transmission on jack and secure it with chains.
9. 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.
10. Apply a light coating of MOPAR(R) High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
11. Raise transmission (2) and align the torque converter with the drive plate and transmission converter housing with the engine block.

12. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.
13. 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.
14. Install the bolts to attach the transmission to the engine. Tighten the bolts to 64 Nm (47 in. lbs.)

CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Failure to follow this caution may result in transmission damage.

15. Rotate crankshaft with socket wrench on dampener bolt in clockwise direction and install NEW torque converter to driveplate bolts. Tighten bolts to 31 Nm (270 in. lbs.).

CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts in the system. Failure to follow this caution may result in damage to the vehicle.





16. Install the power bending bracket onto the extension housing, if equipped. Tighten the power bending bracket nuts (1) to 30 Nm (22 ft.lbs.).Engine Mount Insulator - Installation
17. Install transfer case, if equipped. Tighten transfer case nuts to 35 Nm (26 ft.lbs.).G56 Manual Transmission - Installation
18. Install rear support 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 to 47 Nm (35 ft.lbs.). Tighten the clevis bracket to rear support bolt to 68 Nm (50 ft.lbs.).
20. Remove engine support fixture.










CAUTION: Install the electrical connectors correctly. Some electrical connectors may be interchangeable, damage to the electrical system may occur if the connectors are reversed.

21. Connect wire harnesses to solenoids and transmission range sensor assembly.










22. Install shift cable bracket (1) and the shift cable bracket bolt (5). Tighten bolt to 27 Nm (20 ft.lbs.).
23. Install the shift cable (2) into the shift cable bracket (1).
24. Connect gearshift cable ball socket (3) from transmission manual valve lever (4).




Figure 6 - INPUT AND OUTPUT SPEED SENSORS





25. Connect the wire harness to the input speed sensor (1) and the output speed sensor (2).




Figure 7 - COOLER LINES





26. Connect the electrical harness to torque converter temperature sensor (1) and be certain transmission harnesses are properly routed.
27. Connect cooler lines to transmission (2).
28. Install transmission fill tube.










29. Install bolt (1) securing the differential pressure sensor onto the transmission case. Tighten the bolt to 10 Nm (88 in. lbs.).
30. Install exhaust particulate filter.
31. Align and connect propeller shaft(s).
32. Adjust gearshift cable if necessary.
33. Install any skid plates removed previously. Skid Plate - Installation
34. Lower vehicle.
35. Fill transmission with MOPAR(R) AS68RC Automatic Transmission Fluid. AS68RC Automatic Transmission