Installation

Transmission - Diesel Engines









All vehicles

1. Using the Transmission Jack, raise and position the transmission to the engine and clutch.

2. Install the 7 transmission-to-engine bolts.
- Tighten to 63 Nm (46 lb-ft).

3. Position the crossmember in the vehicle. Install the 3 LH transmission support crossmember bolts.
- Tighten to 70 Nm (52 lb-ft).





4. Install the 4 RH crossmember nuts.
- Tighten to 70 Nm (52 lb-ft).





5. NOTE: The transmission mount studs may have come out of the insulator when the nuts were removed. Install new insulator studs if they came out during removal.

Install the 2 transmission mount nuts.

- Tighten the studs to 75 Nm (55 lb-ft).

- Tighten the nuts to 81 Nm (60 lb-ft).





6. Attach the wire harness to the crossmember.

7. Remove the Transmission Jack.

8. Connect the transmission fluid cooler tubes.
- Tighten to 27 Nm (20 lb-ft).





9. Install the clutch slave cylinder.
- Rotate the clutch slave cylinder clockwise 45 degrees to lock in position.





10. Install the transfer case, if equipped. For additional information, refer to Transfer Case.
- If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned.

11. Install the skid plate, if equipped.

12. NOTE: Make sure the index marks made during removal are aligned.

Connect the driveshaft.

- Tighten the new driveshaft bolts to 111 Nm (82 lb-ft).

13. Install any Power Take-Off (PTO) equipment, if equipped.





14. Connect the reverse lamp switch electrical connector.





15. Connect the wiring harness to the transmission.

16. Refill the transmission to specification. For additional information, refer to Transmission Draining and Filling Procedures.
- Refill the transmission with clean transmission fluid.

17. Install the 2 bolts that attach the shift lever to the transfer case control lever assembly.
- Tighten to 35 Nm (26 lb-ft).

18. NOTICE: Do not use a silicone sealing compound or damage to the components can occur.

NOTE: Do not wait longer than 10 minutes to tighten the 4 bolts due to the rapid cure time of the sealant.

Install the gearshift lever and shift housing assembly.

- Tighten the shift housing-to-case bolts to 23 Nm (17 lb-ft).

- Apply gasket maker to the shift housing and the main case.





19. Install the lower shift lever boot and the 2 screws.





20. Install the upper gearshift lever and bolt.
- Tighten to 35 Nm (26 lb-ft).





21. Install the 4 shift lever boot screws.





Vehicles with a manual shift transfer case

22. Verify the shift sequence from 2H to 4L to 2H.