Installation
INSTALLATIONTransmission
Special Tools:
Special Tool(s)
Installation
All applications
1. CAUTION: Prior to the installation of the transmission and the fluid, the cooler tubes and the Cooler Bypass Valve (CBV) will need to be cleaned. Transmission failure can occur if not cleaned.
CAUTION: Install a new transmission Off-To-Air Cooler (OTA) if the transmission was overhauled or exchanged due to a failure of the transmission. Transmission failure can occur if a new OTA is not used
Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair as required.
2. CAUTION: Prior to the installation of the transmission assembly, the torque converter pilot hub must be correctly lubricated or damage to the torque converter or the engine crankshaft can occur.
Lubricate the torque converter pilot hub with multipurpose grease.
3. CAUTION: Do not use the cooler bypass valve as a handle. Damage to the cooler bypass valve assembly can occur or damage to the case can result.
CAUTION: Be careful not to raise the transmission tip too far. The sensors can make contact with the underbody of the vehicle and cause sensor damage. Sensor failure or leakage can occur.
NOTE: The front of the transmission will need to be lowered in order for the transmission to clear the exhaust system.
Position the transmission.
Raise the rear of the transmission to clear the exhaust.
4. NOTE: The transmission must be in a horizontal position before removing the special tool.
Remove the special tool.
5. Position the upper RH transmission-to-engine bolt.
6. Connect the wire harness to the top of the transmission.
7. While raising the transmission into the engine compartment, make sure to align the fluid filler tube with the stub tube on the transmission. Use the fluid level indicator as a guide.
8. CAUTION: Do not allow the torque converter drive Bets to disengage from the pump gear. Use care not to damage the flexplate and the converter pilot. The torque converter must rest squarely against the flexplate, indicating the converter pilot Is not binding In the crankshaft.
While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.
9. Install seven transmission-to-engine bolts.
10. Connect the transmission wiring harness.
1 Connect the solenoid body connector.
2 Connect the HEGO sensor connector.
3 Connect the two harness routing clips.
11. Install the transmission fluid cooler tubes to the cooler bypass valve.
12. NOTE: The 4x4 is shown, the 4x2 is similar.
Connect the fuel line bracket and install the nut.
13. Connect the Turbine Shaft Sensor (TSS) and the Output Shaft Speed (OSS) sensor.
14. Connect the Digital Transmission (DTR) sensor connector.
15. Connect the shift cable.
1 Install the cable housing to the bracket.
2 Install the shift cable to the manual lever.
16. Install torque converter-to-flexplate nuts.
17. Install the cylinder block opening cover.
18. Install the flexplate inspection cover and bolts.
19. Install the starter motor.
1 Position the starter.
2 Install the two bolts.
3 Install the stud bolt.
20. Connect the starter motor electrical connectors.
21. Install the plastic cover to the starter motor electrical connector.
4x2 applications
22. Install the rear transmission mount and the exhaust hanger.
23. Position the crossmember and loosely install the mount-to-crossmember nuts.
24. Install the six crossmember-to-frame nuts and bolts (three on each side).
25. Lower the transmission on the crossmember and tighten the rear mount nuts.
26. Install the two exhaust heat shield-to-crossmember bolts (one on each side).
27. Remove the transmission jack.
28. Install the driveshaft.
4x4 applications
29. NOTE: To maintain initial driveshaft balance, align the index marks made during removal.
Install the front driveshaft to the front axle pinion flange.
30. Remove the transmission jack.
1 Using a jack stand support the extension housing.
2 Remove the transmission jack.
31. Install the transfer case assembly.
All applications
32. NOTE: If the vehicle is not equipped with a fluid filter, install a fluid filter service kit (XC3Z-7B155-AA) and follow the instructions supplied in the kit. If the vehicle is equipped with a fluid filter, install a new filter (XM-713155-13A).
Install a new in-line transmission fluid filter kit or filter.
33. NOTE: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair, the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is temporary and will return to normal operating condition once the Powertrain Control Module(PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If a concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis.
The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and that this is temporary and will eventually return to normal operating condition.
Connect the battery ground cable.
34. Fill to correct level with clean automatic transmission fluid.