Removal and Installation
REMOVAL1. Shift transmission into first or third gear.
2. Remove the floor console and shift boot as necessary to access the bottom of the shift lever at the shift tower attachment.
3. Install nuts on two M6X1.0 bolts and thread the bolts into the threaded holes at the base of the shift lever.
4. Tighten the nuts equally until the shift lever loosens on the shift tower stub shaft.
5. Remove the shift lever from the shift tower.
6. Raise and support vehicle on suitable safety stands.
7. Support engine with adjustable jack stand. Position wood block between jack and oil pan to avoid damaging pan.
8. Remove skid plate, if equipped.
9. Remove crossmember.
10. Disconnect necessary exhaust system components.
11. Remove slave cylinder (Fig. 1) from clutch housing.
12. Mark rear propeller shaft and rear axle yokes for installation alignment (Fig. 2).
13. Mark front propeller shaft, axle and transfer case yokes for installation alignment, if equipped.
14. Remove propeller shaft(s).
15. Unclip wire harnesses from transmission and transfer case, if equipped.
16. Disconnect transfer case vent hose, if equipped.
17. Disengage any wire connectors attached to transmission or transfer case, if equipped, components.
18. Support transfer case, if equipped, with transmission jack.
19. Secure transfer case, if equipped, to jack with safety chains.
20. Disconnect transfer case shift linkage at transfer case, if equipped.
21. Remove nuts attaching transfer case to transmission, if equipped.
22. Remove transfer case, if equipped.
23. Remove crankshaft position sensor (Fig. 3).
CAUTION: It is important that the crankshaft position sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations.
24. Support engine with adjustable jack stand. Position wood block between jack and oil pan to avoid damaging pan.
25. Support transmission with transmission jack.
26. Secure transmission to jack with safety chains.
27. Disconnect rear cushion and bracket from transmission.
28. Remove rear crossmember.
29. Remove clutch housing-to-engine bolts.
30. Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle.
31. Remove clutch release bearing, release fork and retainer clip.
32. Remove clutch housing from transmission (Fig. 4).
INSTALLATION - TRANSMISSION
1. Install clutch housing on transmission and tighten housing bolts to 46 Nm (34 ft. lbs.).
2. Lubricate contact surfaces of release fork pivot ball stud and release fork with high temp grease.
3. Install release bearing, fork and retainer clip.
4. Position and secure transmission on transmission jack.
5. Lightly lubricate pilot bearing and transmission input shaft splines with Mopar high temp grease.
6. Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place.
7. Install and tighten clutch housing-to-engine bolts to:
Be sure the housing is properly seated on engine block before tightening bolts.
. Tighten 3/8" diameter bolts to 37 Nm (27 ft. lbs.).
� Tighten 7/16" diameter bolts to 58 Nm (43 ft. lbs.).
. Tighten M12 bolts to 75 Nm (55 ft. lbs.).
8. Be sure transmission is in first or third gear.
9. Install rear crossmember and tighten crossmember-to-frame bolts to 41 Nm (31 ft. lbs.).
10. Install fasteners to hold rear cushion and bracket to transmission. Then tighten transmission to-rear support bolts/nuts to 54 Nm (40 ft. lbs.).
11. Remove support stands from engine and transmission.
12. Install and connect crankshaft position sensor.
13. Position transfer case on transmission jack, if equipped.
14. Secure transfer case to jack with safety chains, if equipped.
15. Raise transfer case if equipped and align transfer case input shaft to the transmission output shaft.
16. Slide transfer case forward until case is seated on transmission, if necessary.
17. Install nuts to attach transfer case to transmission, if equipped. Tighten transfer case-to-transmission nuts to 35 Nm (26 ft. lbs.).
18. Connect transfer case shift linkage at transfer case, if equipped.
19. Connect transfer case vent hose, if equipped.
20. Secure wire harnesses in clips/tie straps on transmission and transfer case if equipped.
21. Engage wire connectors attached to all necessary transmission or transfer case, if equipped, components.
22. Install rear propeller shaft slip yoke to transmission or transfer case output shaft if equipped.
23. Install rear propeller shaft with reference marks aligned (Fig. 129).
24. Install and tighten propeller shaft U-joint clamp bolts to 19 Nm (170 inch lbs.).
25. Align marks on front propeller shaft, axle and transfer case yokes, if equipped.
26. Install and tighten propeller shaft U-joint clamp bolts to 19 Nm (170 inch lbs.).
27. Install slave cylinder in clutch housing.
28. Install skid plate, if equipped and tighten bolts to 42 Nm (31 ft. lbs.). Tighten stud nuts to 17 Nm (150 inch lbs.).
29. Fill transmission and transfer case if equipped, with recommended lubricants. Refer to the correct fluid.
30. Lower vehicle.
31. Install nuts on two M6 X 1.0 bolts and thread the bolts into the threaded holes at the base of the shift lever.
32. Tighten the nuts equally until the shift lever will slide over the shift tower stub shaft.
33. Install the floor console and shift boot.