Installation
INSTALLATION - TRANSMISSION1. 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. 130).
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.
30. Lower vehicle.
31. Install nuts on two M6X1.0 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.