Installation

Transmission Installation

CAUTION: Make sure the cooler line system is open and clean before the transmission is installed in vehicle.

CAUTION: 2.3L and 4.0L engines may be equipped with shims located between the engine oil pan and the transmission converter housing. If equipped, these shims must be in place during re-assembly to prevent possible damage to the engine oil pan.

1. Place the transmission on a jack and secure with a safety chain.

2. Rotate the torque converter so the drive studs are in alignment with their holes in the flywheel.

CAUTION: While moving, to avoid damage, do not allow the transmission to get into a nose-down position as this will cause the converter to move forward and disengage from the front pump support and gear . The converter housing is piloted into position by flywheel housing to block dowels in the rear of the cylinder block. The torque converter must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.

3. With the transmission mounted on a transmission jack, move the torque converter and transmission assembly forward into position being careful not to damage the flywheel and the torque converter pilot.

4. Install two converter housing-to-engine attaching bolts at the engine dowel locations. Tighten to 38-51 N-m (28-38 ft-lb) for 2.3L and 4.0L or to 44-60 N-m (33-44 ft-lb) for 3.0L engine.

5. Install the remaining converter housing-to-engine attaching bolts and tighten to 38-51 N-m (28-38 ft-lb) for 2.3L and 4.0L or to 44-60 N-m (33-44 ft-lb) for 3.0L engine.

6. Remove the safety chain from the transmission.

7. Insert the oil filler tube in the lube oil inlet short tube and secure it to the cylinder block with the attaching bolt. Tighten the bolt to 38-51 N-m (28-38 ft-lb). If the oil filler tube is loose in the case it should be replaced.

8. Install the oil cooler lines in the retaining clip at the cylinder block. Connect the lines to the transmission case.

9. Remove the jack supporting the front of the engine.

10. Raise the transmission. Position the front crossmember, rear engine support insulator and support and damper to the frame side supports and install the attaching bolts.

11. Lower the transmission and install the rear engine support-to-crossmember nut.

12. Remove the transmission jack.

13. Install the vacuum hose on the transmission vacuum throttle valve diaphragm. Install the vacuum line into the retaining clip.

14. Connect the park/neutral position switch plug to the park/neutral position switch. Install the overdrive 3/4 shift solenoid connector.

15. Install the four flywheel-to-converter attaching nuts.

When assembling the flywheel to the torque converter, first install the attaching nuts and tighten to 27-46 N-m (20-34 ft-lb).

16. For 3.0L applications, install the converter and engine rear plate bolts. Tighten the bolts to 16-22 N-m (12-16 ft-lb).

17. Install the starter motor and tighten the attaching bolts to 20-27 N-m (15-20 ft-lb).

18. Connect the muffler inlet pipe to the exhaust manifold if disconnected during removal.

19. Connect or install any additional components removed for clearance.

20. Connect the transmission shift cable and bracket to the manual control lever.

21. Connect the transmission shift bellcrank to the throttle valve outer lever.

22. Install the output shaft so the marks scribed on the output shaft and rear axle flange are in alignment. Tighten the circular flange attaching bolts to 95-130 N-m (70-95 ft-lb).

23. Adjust the transmission shift bellcrank as required. Refer to Cable Adjustment and Routing.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

24. Remove safety stands and lower the vehicle. Connect the battery ground cable.

25. Pour 5 quarts of specified oil into oil filler tube. Start engine and add oil as required to achieve the proper oil level as specified.

26. Check the transmission, converter assembly and oil cooler lines for leaks.