Part 1

Engine





Special Tool(s)





Material

Installation

All vehicles

CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.





1. Position the engine in the vehicle and remove the floor crane and the special tool.





2. Install the RH engine support insulator nuts.





3. Install the radiator and A/C condenser as an assembly.





4. Install the RH radiator support bracket and the two bolts.





5. Install the LH radiator support bracket and the two bolts.





6. Remove the right front lifting bracket.





7. Remove the left side lifting bracket.





8. Using the special tool, install a new seal on the power steering pressure (PSP) hose fitting.





9. Connect the PSP hose to the power steering pump.





10. Install the PSP hose support bracket and the bolt.
11. Raise and support the vehicle.





12. Install the LH engine support insulator bolt.





13. Connect the return hose to the power steering pump.





14. Remove the special tool.





15. NOTE: Make sure the stud and the flexplate marks made during removal line up.

Position the transmission in the vehicle.





16. Install the eight engine-to-transmission retaining bolts.





17. Install the cooler tubes, cooler tube bracket and the wilt





18. Connect the transmission cooler tubes.





19. CAUTION: Use care not to bend or force the transmission cooler tubes. Damage to the tubes or the transmission can occur. Use a wrench to hold the fittings mounted in the transmission.

Connect the cooler tubes to the transmission.





20. Connect the harness retainers.





21. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.

NOTE: Always install new O-ring seals on the vehicle harness connector.

NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.

NOTE: Use petroleum jelly to lubricate the O-ring seals to aid the installation process.

Lubricate and install new O-ring seals on the transmission body electrical connector, connect the electrical connector, and tighten the screw.





22. Connect the electrical connectors.





23. Connect the digital transmission range sensor.





24. Move the rubber boot back into position.





25. NOTE: Match the identifying mark on the nut, stud and flexplate to allow for correct installation.

Install the four torque converter nuts.
^ Rotate the crankshaft to access all the nuts.





26. Connect the LH catalyst monitor connector to the transmission.





27. Connect the LH heated oxygen sensor (H02S) electrical connector retainer and the harness clip to the transmission.





28. If equipped, connect the shift motor electrical connector.





29. Connect the RH H02S electrical connector to the transmission.





30. Connect the RH catalyst monitor connector and the fuel tubes to the bracket.





31. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.

CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in the sequence shown.

NOTE: Align the marks made on the flange and driveshaft during removal.

NOTE: On 2-wheel drive vehicles, align the marks on the transmission output shaft.

Position the driveshaft and install the driveshaft-to-pinion flange bolts in the sequence shown.

4x4 vehicles





32. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.

CAUTION: The driveshaft flange fits tightly on the transfer case flange. To make sure that the driveshaft flange seats squarely on the transfer case flange, tighten the bolts evenly in a cries-cross pattern.

NOTE: Align the marks made on the flange and driveshaft during removal.

Install the rear driveshaft-to-transfer case flange bolts.





33. NOTE: Install new flange bolts and washers.

Position the front driveshaft flange with the location marks aligned and install the retaining bolts finger-tight.





34. NOTE: Use new bolts and U-joint straps.

Install the front driveshaft to the front differential.





35. Tighten the front driveshaft flange bolts in the sequence shown.

All vehicles





36. Position the manual shift lever into PARK.





37. Install the bracket and connect the shift cable.

4x4 vehicles





38. Support the transfer case with a suitable jack stand and remove the transmission jack.





39. Disconnect the safety chain and remove the transmission jack.