Removal and Replacement
TransmissionService Repair No - 44.20.01
Special Service Tools (Part 1):
Special Service Tools (Part 2):
Special Service Tools (Part 3):
Removal
1. Disconnect the battery ground cable.
2. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
3. Remove the engine undershield.
4. Remove the radiator splash shield.
5. Remove the front driveshaft.
6. Remove the rear driveshaft.
7. Disconnect the transfer case 3 electrical connectors.
8. Release the selector cable and lever.
Remove the 2 bolts.
Remove the nut.
9. Release the 2 heated oxygen sensor (HO2S) harness brackets.
Remove the 2 bolts.
10. Release the wiring harness from the RH side of the transmission.
Disconnect the electrical connector.
11. Release the wiring harness from the top of the transmission.
12. CAUTION: Always plug any open connections to prevent contamination.
Release the transmission fluid lines.
Remove the bolt.
Remove and discard both O-ring seals.
13. Remove the CKP sensor.
Disconnect the electrical connector.
Remove the Torx(R) screw.
14. Release the flexplate.
Remove the access plugs.
Rotate the crankshaft to access the retaining bolts.
Remove the 3 bolts.
15. Release the starter motor heat shield.
Remove the 2 bolts.
Remove the bracket.
16. Release the front driveshaft joint heat shield from the transmission and carefully move aside.
Remove the nut.
17. WARNING: Secure the transmission to the transmission jack.
WARNING: Support the engine. The engine will fall forward when the transmission is removed.
CAUTION: Make sure the torque converter remains connected to the transmission.
With assistance, remove the transmission.
Using a transmission jack, support the transmission.
Remove the 14 bolts.
18. Install the torque converter retainer.
19. NOTE: Do not disassemble further if the component is removed for access only.
Remove the transmission from the transmission jack.
20. Remove the torque converter retainer.
21. Using the special tools, remove the torque converter.
22. Carefully remove and discard the torque converter fluid seal.
23. CAUTION: Always plug any open connections to prevent contamination.
Disconnect the transfer case breather line.
Depress the locking ring.
24. CAUTION: Always plug any open connections to prevent contamination.
Remove the transmission breather lines.
Depress the locking ring.
Remove the bolt.
25. Remove the transmission support insulator.
Remove the 5 bolts.
26. Remove the transfer case.
Remove the 8 bolts.
Remove the O-ring seal.
Installation
1. Install the transfer case.
Clean the component mating faces.
Lubricate input shaft splines with 'Weicon TL7391' grease.
Install the O-ring seal.
Align the fuel hose support bracket.
Using the special tool, tighten the bolts to 45 Nm (33 ft. lbs).
2. Install the transmission support insulator.
Clean the component mating faces.
Tighten the bolts to 60 Nm (44 ft. lbs).
3. Attach the transmission and the transfer case breather lines.
Tighten the bolt to 10 Nm (7 ft. lbs).
4. Using the special tool, install a new torque converter fluid seal.
Clean the seal register.
5. Install the torque converter.
Clean the seal contact area.
Remove the special tools.
6. Install the torque converter retainer.
7. Position the transmission to the transmission jack.
8. Remove the torque converter retainer.
9. CAUTION: Apply grease of the correct specification to the torque converter spigot.
With assistance, install the transmission.
Clean the component mating faces.
Tighten the bolts to 45 Nm (33 ft. lbs).
10. Secure the front driveshaft joint heat shield.
Tighten the nut to 10 Nm (7 ft. lbs).
11. Secure the starter motor heat shield.
Install the bracket.
Tighten the M10 bolt to 45 Nm (33 ft. lbs).
Tighten the M6 bolt to 10 Nm (7 ft. lbs).
12. Attach the flexplate to the torque converter.
Rotate the crankshaft to access the retaining bolts.
Tighten the bolts to 45 Nm (33 ft. lbs).
Install the access plugs.
13. Install the CKP sensor.
Tighten the Torx(R) screw to 8 Nm (6 ft. lbs).
Connect the electrical connector.
14. Attach the transmission fluid lines.
Clean the components.
Install the new O-ring seals.
Tighten the bolt to 10 Nm (7 ft. lbs).
15. Secure the wiring harness to the transmission.
16. Attach the HO2S harness brackets.
Tighten the bolts to 10 Nm (7 ft. lbs).
17. Install the selector cable and lever.
Tighten the nut to 12 Nm (9 ft. lbs).
Tighten the bolts to 10 Nm (7 ft. lbs).
18. Connect the transfer case electrical connectors
19. Install the rear driveshaft.
20. Install the front driveshaft.
21. Install the radiator splash shield.
22. Install the engine undershield.
23. Connect the battery ground cable.
24. Adjust the selector cable.
25. Check and top-up the transmission fluid level.