Installation

Transmission

Special Tool(s):

Material:

All vehicles
1. Using the transmission jack, raise and position the transmission to the engine and clutch.





2. Install the transmission-to-engine bolts.
^ For vehicles equipped with diesel engines, install 6 bolts.
^ For vehicles equipped with gasoline engines, install 7 bolts.
^ Tighten to 63 Nm (46 ft. lbs.).





3. Position the crossmember in the vehicle. Install the transmission mount nuts.
^ Tighten to 81 Nm (60 ft. lbs.).





4. Install the LH crossmember bolts.
^ Tighten to 70 Nm (52 ft. lbs.).





5. Install the RH crossmember nuts.
^ Tighten to 70 Nm (52 ft. lbs.).

6. Attach the wire harness to the crossmember.








7. Install the dust cover bolts.
^ 6.0L equipped vehicles do not have a dust cover.
^ Tighten to 28 Nm (21 ft. lbs.).

8. Remove the transmission Jack.





9. Connect the transmission cooler tubes.
^ Tighten to 27 Nm (20 ft. lbs.).





10. Install the clutch slave cylinder.
^ Rotate the clutch slave cylinder clockwise 45 degrees to lock in position.

11. Install the starter.
12. Install the catalytic converter.
13. Install the transfer case, if equipped.
^ If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned.

14. Connect the driveshaft.
15. Install any power take-off (PTO) equipment, if equipped.





16. Connect the fuel lines to the transmission.





17. Connect the reverse lamp switch electrical connector.





18. Connect the wiring harness to the transmission.
19. Refill the transmission to specification.
^ Refill the transmission with clean transmission fluid.

20. Lower the vehicle.





21. CAUTION: Do not use a silicone seating compound.

NOTE: Do not wait longer than 10 minutes to tighten the 6 bolts due to the rapid cure time of the sealant.

Install the lower gearshift lever and shift housing assembly.
^ Apply gasket maker to the shift housing and the main case.
^ Tighten to 23 Nm (17 ft. lbs.).





22. Install the lower shift lever boot.





23. Apply threadlock and sealer to the gearshift lever bolts. Install the upper gearshift lever.
^ Tighten to 28 Nm (21 ft. lbs.).





24. Install the screws.





Vehicles with a manual shift transfer case
25. Position the shift lever with the bezel and boot assembly and install the bolt.
^ Tighten to 27 Nm (20 ft. lbs.).





26. Position the bezel and boot assembly and install the screws.
27. Verify the shift sequence from 2H to 4L to 2H.