Installation

INSTALLATION / NV1500 Manual Transmission
1. Install clutch housing on transmission and tighten housing bolts.

housing bolts 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 clutch housing-to-engine bolts and tighten.


clutch housing-to-engine bolts 58 Nm (43 ft. lbs.).

NOTE: Be sure the housing is properly seated on engine block before tightening bolts.

8. Install shift tower and bolts. Tighten bolts.

shift tower bolts 7 - 10 Nm (5 - 7 ft. lbs.).

9. Install rear crossmember and tighten crossmember bolts.

crossmember bolts 41 Nm (31 ft. lbs.).

10. Install transmission mount bolts and tighten.

transmission mount bolts 54 Nm (40 ft. lbs.).


11. Install exhaust bracket to crossmember.
12. Remove support stands from engine and transmission.
13. Install transfer case, shift cable and vent hose if equipped.
14. Install wire connectors to transmission/transfer case.
15. Install propeller shaft/shafts.
16. Install slave cylinder in clutch housing.
17. Install skid plate if equipped.
18. Fill transmission and transfer case if equipped, with recommended lubricants.




EXTENSION HOUSING SEAL / INSTALLATION
1. Place seal in position on transmission housing.






2. Drive new seal into transmission housing with Installer C-3972-A and Handle C-4171.
3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines.
4. Install propeller shaft with reference marks aligned.
5. Remove support and lower vehicle.
6. Check transmission fluid level.