C. Transmission Flush, Torque Converter and Pump Replacement
1. Open the hood.2. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.
3. Raise the vehicle on a suitable hoist.
4. Remove the skid plates.
5. Place a drain container with a large opening under the transmission oil pan.
6. Loosen pan bolts and using a putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain.
7. Remove the transmission oil pan.
8. Remove and discard the transmission oil cooler return filter.
9. Remove and discard the transmission oil pan sump filter.
10. Clean the transmission oil pan.
11. Install the transmission oil pan to the transmission by snugging a few bolts on the transmission oil pan.
12. Paint-mark the transmission and transfer case propeller shafts at the axle companion flanges. The paint marks will be used for assembly alignment.
13. Remove the rear propeller shaft.
14. Remove the front propeller shaft.
15. Disconnect the output speed sensor electrical connector from the transmission.
16. Disconnect the input speed sensor electrical connector from the transmission.
17. Disconnect the transmission solenoid/TRS assembly electrical connector from the transmission.
18. Disconnect the line pressure sensor electrical connector from the transmission.
19. Disconnect the transmission shift cable from the transmission (Figure 3).
20. Disengage the transmission shift cable from the transmission selector lever (Figure 3).
21. Disengage the transmission shift cable from the transmission cable bracket (Figure 3).
22. Remove the starter motor.
23. Remove the rubber access plug above the starter opening to expose the drive plate bolts.
24. Remove the drive plate to torque converter bolts.
25. Remove the exhaust isolators from the exhaust system hanger at the transmission mount crossmember.
26. Remove the transfer case as follows:
a. Disconnect transfer case position sensor electrical connector from the electrical harness.
b. Disconnect transfer case shift cable at the range lever (Figure 3).
c. Disconnect the transfer case shift cable from the shift cable bracket.
d. Remove the transfer case shift cable bracket (Figure 3).
e. Disconnect transfer case vent hose.
f. Secure the transfer case to a suitable transmission jack in accordance to the transmission jack manufacturer's instructions.
g. Remove nuts attaching transfer case to the transmission.
h. Pull the transfer case and jack rearward to separate the transfer case from the transmission.
i. Lower and remove the transfer case from under vehicle and set the transfer case aside.
27. Support the transmission with a suitable transmission jack. Secure the transmission to the transmission jack according to the transmission jack manufacturer's instructions.
28. Remove the transmission crossmember supporting the transmission completely from the vehicle.
29. Remove the transmission dipstick tube assembly.
30. Use special tool # 9546 to disconnect both transmission fluid cooler lines at the transmission.
31. Disconnect the transmission vent hose from the transmission.
32. Remove all bellhousing-to-engine bolts.
33. Carefully separate the transmission assembly from the engine block.
34. Lower the transmission and remove the transmission from under the vehicle.
NOTE:
Hold the torque converter in place during transmission removal.
35. Mark the location of any torque converter bolt lug to the bellhousing.
36. Carefully slide the old torque converter out of the transmission and return it to your parts department for core return.
37. Clean the transmission exterior and the bellhousing interior of road dirt, oil and grease.
38. Install special tool transmission stand tool # 8257.
39. Place the transmission, oil pan side up, on a suitable work bench.
40. Remove the transmission oil pan.
CAUTION:
Be sure your hands and tools are clean before continuing on to the following steps.
41. Remove the outer snap-ring securing the transmission front cover to the transmission case (Figure 4).
42. Remove the inner snap-ring securing the transmission front cover to the oil pump and discard it (Figure 4).
43. Push out the transmission front cover from the transmission case using a blunt tool. Insert the tool through the opening by the transmission oil sump filter boss (Figure 5).
44. Discard the front cover.
45. Remove the bolts holding the oil pump into the transmission case (Figure 6).
46. Push the transmission input shaft towards the transmission while pulling the transmission oil pump out. Discard the old transmission oil pump.
CAUTION:
Do not let the input shaft move forward (away) from the transmission. Forward movement of the input shaft will dislodge the number 2, 3, or 4 bearing inside the input clutch assembly.
47. Carefully install the new oil pump and tighten the bolts to 250 in. lbs. (28 N.m) (Figure 6).
NOTE:
The new transmission oil pump and cover is different from the old components removed. The pump and cover was changed to integrate the torque converter seal into the front cover. The inner snap ring is no longer needed. See Figure 7 and Figure 8.
48. Lightly coat the inner seal lip in the new front cover with AFT+4 transmission oil (Figure 8).
49. Install the new transmission front cover into the transmission case using special tool #9955 and a dead-blow mallet.
50. Install the outer snap-ring to hold the transmission front cover into the transmission case.
51. Install a new transmission oil sump filter. Tighten the screws to to 40 in.lbs. (4.5 N.m).
52. Install a new oil cooler return filter. Using wrench # 8321, tighten the cooler return oil filter to 108 in. lbs. (12 N.m).
53. Clean the transmission oil pan.
54. Clean the transmission oil pan mounting face with a clean lint-free towel.
55. Apply a 1/8" bead of Mopar ATF-RTV (PN 05010884AA) to the oil pan
56. Install the transmission oil pan. Tighten the bolts to 105 in. lbs. (12 N.m).
57. Pour in 1 quart of ATF+4 transmission fluid into the new torque converter opening.
58. Clean the transmission bellhousing cavity.
59. Carefully insert the new torque converter into the transmission. Rotate the converter back and forth until it fully engages the transmission oil pump.
60. Check converter seating and alignment with steel scale and straightedge. Align one of the torque converter bolt boss with the mark on the transmission housing made in Step 35. Check the distance from the surface of converter lug to the straightedge. It should be at least 1/2 in. (13 mm) to rear of straightedge when converter is fully seated (Figure 9).
61. Temporarily secure the torque converter to the transmission bellhousing with a C-clamp.
62. Position transmission on the transmission jack and secure it in accordance with the transmission jack manufacturer's instructions.
63. Apply a light coating of MOPAR Multi-Purpose Grease (PN 05083150AA) or equivalent, to counter bore hole for the torque converter hub at the rear of the engine's crankshaft.
64. Remove the C-clamp from the transmission and raise transmission to the engine. Align the transmission torque converter hub into the hole at the rear of the engine crankshaft. Push the transmission forward and over transmission alignment/engine block dowels.
CAUTION:
Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
65. Install the upper left engine-to transmission bellhousing bolt and tighten snugly.
66. Install the transmission dipstick assembly and position the bracket. Tighten the bracket bolt to 250 in.lbs. (28 N.m).
67. Install the remaining engine-to-transmission bell housing bolts. Tighten all bolts to 50 ft. lbs. (68 N.m).
68. Install the transmission vent hose.
69. Install the transmission crossmember support. Tighten bolts to the chassis to 50 ft.lbs. (68 N.m).
70. Lower transmission onto the crossmember and install the bolts attaching transmission mount to cross member. Tighten the bolts to 35 ft. lbs. (47 N.m).
71. Remove the transmission jack.
72. Install the transfer case as follows:
a. Secure the transfer case to a suitable transmission jack in accordance to the transmission jack manufacturer's instructions.
b. Install the transfer case to the rear of the transmission. Tighten transfer case to transmission nuts to 26 ft. lbs. (35 N.m).
c. Install the transfer case shift cable bracket and tighten the bolts to 250 in. lbs. (28 N.m).
d. Remove the transmission jack.
e. Install the transfer case vent hose.
f. Install the transfer case shift cable to the shift cable bracket.
g. Install the transfer case shifter cable to the range lever.
h. Connect the wiring harness connector to the transfer case position sensor.
73. Align the torque converter to the drive plate and install the bolts. Tighten the bolts to 23 ft.lbs. (31 N.m)
74. Install the rubber drive plate bolt access plug into the opening above the starter.
75. Install the starter motor and cooler line bracket. Tighten the bolts to 40 ft. lbs. (54 N.m).
76. Attach the transmission shift cable to the cable support bracket.
77. Connect the transmission shift cable to the transmission gear selector arm.
78. Connect the wire harness connector to the transmission line pressure sensor.
79. Connect the wire harness connector to the transmission solenoid/TRS assembly connector.
80. Connect the wire harness connector to the input speed sensor.
81. Connect the wire harness connector to the output speed sensor.
82. Align the front propeller shaft to the paint mark made in Step 12. Install the propeller shaft companion flange bolts and tighten to 22 ft. lbs. (30 N.m).
83. Align the rear propeller shaft to the paint mark made in Step 12. Install the propeller shaft companion flange bolts and tighten to 85 ft. lbs. (115 N.m).
84. Disconnect the transmission oil cooler lines at the A/C condenser/Transmission Oil Cooler (TOC) unit.
85. From the transmission end, use shop air and blow out any debris in both transmission cooler lines.
86. Connect the transmission cooler lines to the transmission.
87. Install the transfer case skid plate and tighten the bolts to 25 ft.lbs. (34 N.m).
88. Install the front skid plate and tighten the bolts to 45 ft.lbs. (61 N.m)
89. Lower the vehicle.
90. Discharge the A/C system using an appropriate refrigerant recovery system.
91. Remove the grille.
92. Remove the radiator support crossmember as follows (Figure 10):
a. Remove the five bolts on the radiator support crossmember.
b. Remove the two bolts holding the hood latch bracket to the bumper reinforcement.
c. Remove the washer reservoir cap/collar from the reservoir bottle.
93. Set the radiator support crossmember on top of the engine.
94. Remove the upper air deflector on the right side of the A/C condenser/TOC unit.
95. Disconnect the electric radiator fan connector from the wiring harness (Figure 11).
96. Remove the nuts that secure the A/C discharge and liquid lines to the A/C condenser/TOC.
97. Remove and discard the O-ring seals from the A/C discharge and liquid lines.
98. Move the A/C discharge and liquid lines aside.
99. Remove the three bolts securing the electric radiator fan.
100. Remove the right and left bolts securing the Grill Opening Reinforcement (GOR) to the radiator support crossmember mounting stanchion behind each headlamp (Figure 12).
101. Pull the GOR forward slightly and pull the electric radiator fan up and remove it from the vehicle (Figure 13).
CAUTION:
Do not damage the tab on the GOR during fan removal or installation (Figure 13).
102. Remove the right and left bolts that secure the A/C condenser/transmission oil cooler (TOC) unit (Figure 14 shows only the left side bolt).
103. Carefully lift the A/C condenser/TOC straight up to disengage the lower brackets from the radiator and remove the A/C condenser/TOC unit from the vehicle.
104. Carefully lower the new A/C condenser/TOC unit into the vehicle and engage the lower condenser brackets to the radiator.
105. Install the two bolts that secure the A/C condenser/TOC unit brackets to the radiator (Figure 14). Tighten the bolts to 44 in.lbs. (5 N.m).
106. Connect the two transmission cooling lines to the A/C condenser/TOC unit (Figure 15).
107. Pull the GOR slightly forward and lower the electric cooling fan between the GOR and the A/C condenser/TOC unit (Figure 13).
108. Insert the electric radiator fan dowel pin located at the top left (as you are facing the engine) into the locating hole (Figure 11). Install and tighten the three bolts to 80 in. lbs. (9 N.m).
109. Install the right and left bolts fastening the GOR to the front cross member mounting stanchion behind each headlamp (Figure 12). Tighten the bolts to 85 in. lbs. (10 N.m).
110. Connect the electric radiator fan electrical connector to the wiring harness connector.
111. Add 1 fluid ounce (30 milliliters) of Mopar PAG type refrigerant oil (PN 82300102) to the into either A/C line opening of the A/C condenser/TOC unit.
112. Lubricate the new rubber "O" ring seals with clean refrigerant oil and install them onto the refrigerant line fittings.
113. Connect the A/C liquid and discharge lines to A/C condenser/TOC unit and install the retaining nuts. Tighten the nuts to 200 in.lbs. (22.5 N.m).
114. Install the upper air deflector to the right side of the A/C condenser/TOC unit.
115. Install the upper radiator crossmember as follows:
a. Install the washer reservoir cap/collar to the neck of the washer reservoir bottle.
b. Position the cross member.
c. Install the two bolts holding the hood latch bracket to the bumper reinforcement and tighten to 85 in. lbs. (10 N�m).
d. Install the five bolts securing the cross member. Tighten the bolts to 85 in. lbs. (10 N.m).
116. Install the grille.
117. Evacuate the A/C system.
118. Charge the A/C system with R-134A refrigerant.
119. Connect the negative battery cable.
120. Pour in 5 quarts of Mopar ATF+4 (PN 05013458AA or 05013457AA) into the transmission oil fill tube.
121. Start the vehicle and shift transmission through all gear ranges then back to NEUTRAL.
122. Bring the transmission fluid up to its normal operating temperature.
123. With the vehicle parking brake applied, engine running and the transmission in PARK, adjust the transmission fluid level as needed. needed.
124. Continue with either Section D for 2006 model year vehicles or Section E for 2005 model year vehicles.