Installation

Transmission









Installation

All vehicles

NOTICE: Install a new Oil-To-Air (OTA) cooler as part of a transmission overhaul, or when installing a remanufactured transmission due to major metallic failure, multiple clutches or clutch plate failures or sufficient component wear, which results in metallic contamination.

NOTICE: Prior to installation of a new or overhauled transmission, clean the transmission fluid cooler tubes. Otherwise transmission failure can occur.

1. When an overhauled or remanufactured transmission is installed, flush and clean the transmission fluid cooler tubes, then verify fluid flow to prevent repeat repairs. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning Procedures and Transmission Fluid Cooler Component Tests and General Diagnostics.

2. For vehicles equipped with a Power Take-Off (PTO) assembly, prior to installing the transmission, flush and clean the PTO assembly to remove any foreign material. Failure to remove foreign material from the PTO assembly may result in subsequent transmission concerns.

3. NOTICE: Prior to installation of the transmission, lubricate the torque converter pilot hub or damage to the torque converter or engine crankshaft can occur.

Lubricate the torque converter pilot hub with multi-purpose grease.





4. Rotate the torque converter so the green or orange paint daub on the converter is in the 12 o'clock position.

5. If the Torque Converter Retainer has not been installed during the assembly of the transmission, install the Torque Converter Retainer to hold the torque converter in place while moving and positioning the transmission in place. Once the transmission is in place, prior to bolting it to the engine, remove the Torque Converter Retainer.





6. Install a new transmission fluid filler tube O-ring.





7. Position the transmission. While raising the transmission up into the engine compartment, use the transmission fluid level indicator as a guide and align the transmission fluid filler tube with the stub tube on the transmission.

While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.





8. Install the 7 transmission-to-engine bolts.
- Tighten to 47 Nm (35 lb-ft).





9. Using a suitable tool, rotate the crankshaft pulley to provide access for the installation of the torque converter-to-flexplate nuts.





10. Install the 6 new torque converter-to-flexplate nuts.
- Tighten to 48 Nm (35 lb-ft).





11. Install the cylinder block opening cover.





12. Install the steering damper and install the steering damper-to-frame bolt and nut.
- Tighten to 103 Nm (76 lb-ft).





13. Install the starter motor. For additional information, refer to Starting System - Gasoline Engines Service and Repair.

14. Install the front transmission fluid cooler tube.
- Tighten to 40 Nm (30 lb-ft).





15. Install the rear transmission fluid cooler tube.
- Tighten to 40 Nm (30 lb-ft).





16. Install the flexplate inspection cover.

1. Position the flexplate inspection cover.

2. Install the flexplate inspection cover bolts.
- Tighten to 34 Nm (25 lb-ft).





17. If required, install new transmission insulator studs.
- Tighten to 75 Nm (55 lb-ft).

18. Install the transmission insulator and the new transmission insulator-to-extension housing bolts.
- Tighten to 103 Nm (76 lb-ft).





19. Install the transmission support crossmember. For additional information, refer to Full Frame and Body Mounting Service and Repair.

20. NOTICE: Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install the 3 new LH engine support insulator nuts.

- Tighten to 200 Nm (148 lb-ft).





21. NOTE: The RH engine support insulator studs may come out of the insulator while removing the nuts. Install new RH engine support insulator studs if the studs come out.

If required, install the new RH engine support insulator stud (W790018).

- Tighten to 80 Nm (59 lb-ft).

22. NOTICE: Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install the 4 new RH engine support insulator nuts.

- Tighten to 115 Nm (85 lb-ft).





23. NOTE: RH shown, LH similar.

Connect the RH and LH wiring harness to the side of the transmission.





24. Connect the Output Shaft Speed (OSS) sensor.





25. Connect the Turbine Shaft Speed (TSS)/intermediate shaft speed sensor.





26. Connect the transmission vehicle harness connector.
- Tighten to 5 Nm (44 lb-in).





27. NOTE: If the vehicle is equipped with a PTO unit, all or part of the PTO unit will need to be installed.

NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable assembly between the manual control lever and the selector lever cable bracket.

Install the selector lever cable.

1. Install the selector lever cable bracket and selector lever cable bracket bolts.
- Tighten to 48 Nm (35 lb-ft).

2. Connect the selector lever cable to the manual control lever.





Four-Wheel Drive (4WD) vehicles

28. Install the transfer case assembly. For additional information, refer to Transfer Case .

Vehicles equipped with 4WD and a manual shift transfer case

29. Install the transfer case linkage bracket and loosely install the bolt.





30. Install the transfer case linkage and install the bolt.
- Tighten to 40 Nm (30 lb-ft).





31. Tighten the transfer case linkage bracket bolt.
- Tighten to 40 Nm (30 lb-ft).





Rear Wheel Drive (RWD) vehicles

32. NOTE: Align index marks made during removal.

NOTE: Install new bolts and retainers.

Connect the driveshaft to the transmission and install the 4 new driveshaft-to-transmission flange bolts.

- Tighten to 103 Nm (76 lb-ft).





All vehicles

33. Install the exhaust Y-pipe. For additional information, refer to Exhaust System .

34. Connect the battery. For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

35. Fill the transmission with clean transmission fluid.

36. Adjust the selector lever cable. Verify the vehicle starts in PARK and NEUTRAL and the reverse lamps illuminate in REVERSE. For additional information, refer to Automatic Transaxle/Transmission External Controls Adjustments.

37. NOTICE: Using transmission fluid other than what is specified can result in the transmission failing to operate in a normal manner or transmission failure.

Using the scan tool with the engine running, make sure the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.

38. If the torque converter was replaced, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.