B. Torque Converter 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. Paint-mark the transmission and transfer case propeller shafts at the axle companion flanges. The paint marks will be used for assembly alignment.
6. Remove the rear propeller shaft.
7. Remove the front propeller shaft.
8. Disconnect the output speed sensor electrical connector from the transmission.
9. Disconnect the input speed sensor electrical connector from the transmission.
10. Disconnect the transmission solenoid/TRS assembly electrical connector from the transmission.
11. Disconnect the line pressure sensor electrical connector from the transmission.
12. Disconnect the transmission shift cable from the transmission position selector lever (Figure 1).
13. Disengage the transmission shift cable from the transmission cable bracket (Figure 1).
14. Remove the starter motor.
15. Remove the rubber access plug above the starter motor opening to expose the drive plate bolts.
16. Remove the drive plate to torque converter bolts.
17. Remove the exhaust isolators from the exhaust system hanger at the transmission mount crossmember.
18. 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 1).
c. Disconnect the transfer case shift cable from the shift cable bracket.
d. Remove the transfer case shifter cable bracket (Figure 1).
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. Set the transfer case aside.
19. Support the transmission with a suitable transmission jack. Secure the transmission to the transmission jack according to the transmission jack manufacturer's instructions.
20. Remove the transmission crossmember supporting the transmission completely from the vehicle.
21. Remove the transmission dipstick tube assembly.
22. Use special tool # 9546 to disconnect both transmission fluid cooler lines at the transmission.
23. Disconnect the transmission vent hose from the transmission.
24. Remove all bellhousing-to-engine bolts.
25. Carefully separate the transmission assembly from the engine block.
26. Lower the transmission and remove the transmission from under the vehicle.
NOTE:
Hold the torque converter in place during transmission removal.
27. Mark the location of any torque converter bolt lug to the bellhousing.
28. Carefully slide the old torque converter out of the transmission and return it to your parts department for core return.
29. Pour in 1 quart of ATF+4 transmission fluid into the new torque converter opening.
30. Clean the transmission bell housing cavity.
31. Carefully insert the new torque converter into the transmission. Rotate the converter back and forth until it fully engages the transmission oil pump.
32. Check the torque converter seating and alignment with steel scale and straightedge. Align one of the torque converter bolt lugs with the mark on the transmission housing made in Step 27. Check the distance from the surface of converter bolt lug to the straight edge. It should be at least 1/2 in. (13 mm) to rear of straight edge when converter is fully seated (Figure 2).
33. Temporarily secure the torque converter to the transmission bellhousing with a C-clamp.
34. Apply a light coating of MOPAR Multi-Purpose Grease (PN 05083150AA) or equivalent, to the torque converter hub.
35. Remove the C-clamp from the transmission and raise the 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 the 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.
36. Install the upper left engine-to transmission bellhousing bolt and tighten snugly.
37. Install the transmission dipstick assembly and position the bracket. Tighten the bracket bolt to 250 in. lbs. (28 N.m).
38. Install the remaining bellhousing to engine bolts. Tighten all bolts to 50 ft.lbs. (68 N.m).
39. Install the transmission vent hose.
40. Install the transmission fluid cooler lines at the transmission.
41. Install the transmission crossmember support. Tighten the chassis bolts to 50 ft. lbs. (68 N.m).
42. Lower the transmission onto the crossmember and install the bolts attaching the transmission mount to crossmember. Tighten the bolts to 35 ft. lbs. (47 N.m).
43. Remove the transmission jack.
44. 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 the transfer case to transmission retaining 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.
45. Align the torque converter to the drive plate and install the bolts. Tighten the bolts to 23 ft.lbs. (31 N.m)
46. Install the rubber drive plate bolt access plug into the opening above the starter.
47. Install the starter motor and cooler line bracket. Tighten the starter bolts to 40 ft.lbs. (54 N.m).
48. Attach the transmission shift cable to the cable support bracket.
49. Connect the transmission shift cable to the transmission gear selector arm.
50. Connect the wire harness connector to the transmission line pressure sensor.
51. Connect the wire harness connector to the transmission solenoid/TRS assembly connector.
52. Connect the wire harness connector to the input speed sensor.
53. Connect the wire harness connector to the output speed sensor.
54. Align the front propeller shaft to the paint mark made in Step 5. Install the propeller shaft bolts and tighten to 22 ft. lbs. (30 N.m).
55. Align the rear propeller shaft to the paint mark made in Step 5. Install the propeller shaft bolts and tighten to 85 ft. lbs. (115 N.m).
56. Install the transfer case skid plate and tighten the bolts to 25 ft. lbs. (34 N.m).
57. Install the front skid plate and tighten the bolts to 45 ft. lbs. (61 N.m).
58. Lower the vehicle.
59. Add about a pint of ATF+4 transmission oil to the transmission.
60. Reconnect the negative battery cable.
61. Start the vehicle and shift transmission through all gear ranges then back to NEUTRAL.
62. Bring the transmission fluid up to its normal operating temperature.
63. With the vehicle parking brake applied, the engine running and the transmission in PARK, adjust the transmission fluid level as needed.
64. Continue with either Section D for 2006 model year vehicles or Section E for 2005 model year vehicles.