Transmission Replacement
Transmission Replacement
Removal Procedure
Important: The following transmission replacement procedure serves as a guide. In order to provide enough clearance for removal of the transmission, removal of other components may be necessary on some vehicles. Information on the removal of other components are not included in this transmission replacement procedure.
1. Block the wheels.
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
2. Disconnect the negative battery cable.
3. Drain the transmission oil. Refer to Automatic Transmission Fluid and Filter Replacement Allison - Automatic Transmission.
4. Cover the oil pan opening in order to prevent the entry of foreign material.
5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Fluid Filler Tube and Seal Replacement (8.1L w/AT545 and MTs) Transmission Fluid Filler Tube and Seal Replacement (8.1L w/AT545 and MTs)Transmission Fluid Filler Tube and Seal Replacement (7.2L w/AT545 and MTs) Transmission Fluid Filler Tube and Seal Replacement (7.2L w/AT545 and MTs)Transmission Fluid Filler Tube and Seal Replacement (7.2L wMD series) Transmission Fluid Filler Tube and Seal Replacement (7.2L wMD series).
6. Disconnect the oil cooler lines from the transmission. Refer to Oil Cooler Hose/Pipe Replacement (8.1L with MT 643/MT653) Oil Cooler Hose/Pipe Replacement (8.1L with MT 643/MT653)Oil Cooler Hose/Pipe Replacement (8.1L with AT545) Oil Cooler Hose/Pipe Replacement (8.1L with AT545)Oil Cooler Hose/Pipe Replacement (7.2L MT643/653 Filter on Right) Oil Cooler Hose/Pipe Replacement (7.2L MT643/653 Filter on Right)Oil Cooler Hose/Pipe Replacement (7.2L with MD Series) Oil Cooler Hose/Pipe Replacement (7.2L with MD Series)Oil Cooler Hose/Pipe Replacement (7.2L with AT545) Oil Cooler Hose/Pipe Replacement (7.2L with AT545)Oil Cooler Hose/Pipe Replacement (7.2L MT Filter on Left) Oil Cooler Hose/Pipe Replacement (7.2L MT Filter on Left).
7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement (Steering Column) Shift Cable Replacement (Steering Column)Shift Cable Replacement (Floor Shift) Shift Cable Replacement (Floor Shift)Shift Cable Replacement (Console Shift) Shift Cable Replacement (Console Shift).
8. Remove the modulator from the transmission.
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:
* One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement
* Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement
* Three-Piece Propeller Shaft Replacement Three-Piece Propeller Shaft Replacement
12. Disconnect the parking brake cable, if equipped. Refer to Park Brake Cable Replacement .
Notice: Refer to Transmission Removal Notice in Cautions and Notices.
13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts:
* If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.
* If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.
1. Remove the flywheel housing access cover.
2. Turn the flex plate using a pry bar in order to align the torque convertor bolts with the access hole.
3. Remove the torque convertor bolts.
14. Remove the transmission rear support beam, if equipped.
15. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing.
16. Support the rear of the engine on a jack stand.
17. Remove the bolts securing the transmission to the engine.
18. Support the transmission with a transmission dolly that can support a load of at least 349 kg (750 lb).
1. Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.
2. Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.
3. Lower the transmission.
4. Remove the transmission from the vehicle.
Installation Procedure
Notice: Refer to Transmission Installation Interference Notice in Cautions and Notices.
1. Use a transmission dolly that can support a load of at least 349 kg (750 lb), to lift the transmission into place.
1. Move the transmission forward.
2. Align the torque converter with the pilot hole in the engine flex plate.
3. Secure the transmission to the engine.
Notice: Refer to Fastener Notice in Cautions and Notices.
2. Install the transmission to engine bolts.
Tighten the transmission to engine bolts to 55 Nm (41 lb ft).
3. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.
4. Install the torque converter to flywheel bolts.
Tighten the torque converter to flywheel bolts to 67 Nm (49 lb ft).
5. Install the flywheel housing access cover.
6. Install the transmission rear support beam, if equipped.
7. Install the transmission rear support beam to transmission nuts.
Tighten the support beam nuts to 105 Nm (77 lb ft).
8. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Engine Mount Replacement .
9. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.
Tighten the cushion to the bracket nuts to 45 Nm (33 lb ft).
10. Install the cushion to support nuts and the shims, as needed.
Tighten the cushion to support nuts to 31 Nm (23 lb ft).
11. Connect the parking brake cable. Refer to Park Brake Cable Replacement .
12. Connect the oil cooler lines to the transmission. Refer to Oil Cooler Hose/Pipe Replacement (8.1L with MT 643/MT653) Oil Cooler Hose/Pipe Replacement (8.1L with MT 643/MT653)Oil Cooler Hose/Pipe Replacement (8.1L with AT545) Oil Cooler Hose/Pipe Replacement (8.1L with AT545)Oil Cooler Hose/Pipe Replacement (7.2L MT643/653 Filter on Right) Oil Cooler Hose/Pipe Replacement (7.2L MT643/653 Filter on Right)Oil Cooler Hose/Pipe Replacement (7.2L with MD Series) Oil Cooler Hose/Pipe Replacement (7.2L with MD Series)Oil Cooler Hose/Pipe Replacement (7.2L with AT545) Oil Cooler Hose/Pipe Replacement (7.2L with AT545)Oil Cooler Hose/Pipe Replacement (7.2L MT Filter on Left) Oil Cooler Hose/Pipe Replacement (7.2L MT Filter on Left).
13. Install the oil level indicator tube. Refer to Transmission Fluid Filler Tube and Seal Replacement (8.1L w/AT545 and MTs) Transmission Fluid Filler Tube and Seal Replacement (8.1L w/AT545 and MTs)Transmission Fluid Filler Tube and Seal Replacement (7.2L w/AT545 and MTs) Transmission Fluid Filler Tube and Seal Replacement (7.2L w/AT545 and MTs)Transmission Fluid Filler Tube and Seal Replacement (7.2L wMD series) Transmission Fluid Filler Tube and Seal Replacement (7.2L wMD series).
14. Connect the speedometer sensor harness.
15. Install the propeller shaft to the transmission. Refer to the necessary procedure:
* One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement
* Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement
* Three-Piece Propeller Shaft Replacement Three-Piece Propeller Shaft Replacement
16. Install the modulator to the transmission.
17. Connect the shift cable to the transmission. Refer to Shift Cable Replacement (Steering Column) Shift Cable Replacement (Steering Column)Shift Cable Replacement (Floor Shift) Shift Cable Replacement (Floor Shift)Shift Cable Replacement (Console Shift) Shift Cable Replacement (Console Shift).
18. Connect any additional lines, hose, or wires, as required.
19. Fill the transmission with oil. Refer to Automatic Transmission Fluid and Filter Replacement Allison - Automatic Transmission.
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
20. Connect the negative battery cable.
21. Check the transmission oil level. Refer to Fluid Capacity Specifications [1][2]Capacity Specifications.
22. Remove the wheel blocks.