300, Magnum, 2005

Transmission Removal & Installation

Print

42rle



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Mark driveshaft and the transmission flange for assembly alignment.
  8.  
  9. Remove the bolts holding the rear driveshaft coupler to the transmission flange.
  10.  
  11. Slide the driveshaft rearward until the coupler clears the driveshaft pilot on the transmission output shaft.
  12.  
  13. Remove the bolts holding the starter motor to the transmission.
  14.  
  15. Remove the starter from the transmission starter pocket and safely relocate.
  16.  
  17. Remove the bolt holding the torque converter access cover to the transmission, 3.5L engines.
  18.  
  19. Remove the torque converter access cover from the transmission.
  20.  
  21. Remove the structural collar bolts and structural collar on vehicles equipped with 2.7L engines.
  22.  
  23. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  24.  
  25. Disconnect the gearshift cable from the transmission manual valve lever.
  26.  
  27. Loosen the bolts holding the shift cable retaining strap to the transmission.
  28.  
  29. Remove the shift cable from the transmission.
  30.  
  31. Disconnect wires from the input and output speed sensors.
  32.  
  33. Disconnect wires from the transmission range sensor.
  34.  
  35. Disconnect wires from the solenoid/pressure switch assembly.
  36.  
  37. Remove the crankshaft position sensor.
  38.  
  39. Remove the bolt holding the transmission fill tube to the transmission.
  40.  
  41. Remove the transmission fill tube.
  42.  
  43. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  44.  
  45. Disconnect the transmission vent hose from the transmission.
  46.  
  47. Support rear of engine with safety stand or jack.
  48.  
  49. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  50.  
  51. Remove bolts securing rear support and cushion to transmission crossmember.
  52.  
  53. Remove bolts attaching crossmember to frame and remove crossmember.
  54.  
  55. Remove the bolts holding the engine oil pan to the transmission.
  56.  
  57. Remove all remaining bolts holding the engine to the transmission.
  58.  
  59. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  60.  
  61. Hold torque converter in place during transmission removal.
  62.  
  63. Lower transmission and remove assembly from under the vehicle.
  64.  
  65. To remove torque converter, carefully slide torque converter out of the transmission.

    Click image to see an enlarged view

    Fig. Rear crossmember cushion-42RLE



    Click image to see an enlarged view

    Fig. Transmission-to-oil pan bolts-42RLE

  66.  

To install:

  1. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation.
  2.  
  3. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
  4.  
  5. Lubricate oil pump seal lip with transmission fluid.
  6.  
  7. Place torque converter in position in transmission.
    WARNING
    Do not damage oil pump seal or converter hub while inserting torque converter into the front of the transmission.

  8.  
  9. Align torque converter to oil pump seal opening.
  10.  
  11. Insert torque converter hub into oil pump.
  12.  
  13. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears.
  14.  
  15. Check converter seating with a scale and straight-edge at -A-. Surface of converter lugs should be at least 19 mm ( 3 / 4 in.) to rear of straight-edge when converter is fully seated.
  16.  
  17. If necessary, temporarily secure converter with C-clamp attached to the converter housing.
  18.  
  19. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
  20.  
  21. Apply a light coating of Mopar° High Temp Grease to the torque converter hub pocket in the rear pocket of the engine-s crankshaft.
  22.  
  23. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
  24.  
  25. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
  26.  
  27. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
  28.  
  29. Install two bolts to attach the transmission to the engine.
  30.  
  31. Install remaining torque converter housing to engine bolts. Tighten to 29 ft. lbs. (39 Nm).
  32.  
  33. Install rear transmission crossmember. Tighten crossmember to frame bolts to 50 ft. lbs. (68 Nm).
  34.  
  35. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  36.  
  37. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 39 ft. lbs. (47 Nm).
  38.  
  39. Remove engine support fixture.
  40.  
  41. Install the transmission to engine oil pan bolts. Tighten to 29 ft. lbs. (39 Nm).
  42.  
  43. Connect input and output speed sensor wires and the transmission range sensor.
  44.  
  45. Connect wires to the solenoid/pressure switch assembly.
  46.  
  47. Install the crankshaft position sensor.
  48.  
  49. Connect the gearshift cable to the transmission manual shift lever.
    WARNING
    It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

  50.  
  51. Install all torque converter-to-driveplate bolts by hand.
  52.  
  53. Verify that the torque converter is pulled flush to the driveplate. Tighten bolts to 31 ft. lbs. (42 Nm).
  54.  
  55. Install the torque converter bolt access cover onto the transmission, for vehicles equipped with 3.5L engines. Install the access cover bolt and tighten to 96 inch lbs. (11 Nm).
  56.  
  57. Install the structural collar and bolts for vehicles equipped with a 2.7L engine.
  58.  
  59. Install starter motor.
  60.  
  61. Connect the cooler line fittings and cooler lines to the transmission.
    NOTE
    Inspect the fill tube grommet to determine if the grommet is new or used. If a new fill tube grommet is in the transmission case, pierce the center of the grommet with a ballpoint pen, or similar instrument, to prepare the grommet for the fill tube installation.

  62.  
  63. Install the transmission fill tube.
  64.  
  65. Install exhaust components.
  66.  
  67. Align and connect the driveshaft.
  68.  
  69. Adjust gearshift cable if necessary.
  70.  
  71. Lower vehicle.
  72.  
  73. Connect negative battery cable.
  74.  
  75. Fill transmission with appropriate transmission fluid.
  76.  
  77. Verify proper operation.
  78.  

NAG1 Transmission



  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure using the scan tool.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Mark driveshaft and the transmission flange for assembly alignment.
  8.  
  9. Remove the bolts holding the rear driveshaft coupler to the transmission flange.
  10.  
  11. Slide the driveshaft rearward until the coupler clears the driveshaft pilot on the transmission output shaft.
  12.  
  13. Remove the bolts holding the starter motor to the transmission.
  14.  
  15. Remove the starter from the transmission starter pocket and safely relocate.
  16.  
  17. Remove the bolt holding the torque converter access cover to the transmission.
  18.  
  19. Remove the torque converter access cover from the transmission.
  20.  
  21. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  22.  
  23. Disconnect the gearshift cable) from the transmission manual valve lever.
  24.  
  25. Loosen the bolts holding the shift cable retaining strap to the transmission.
  26.  
  27. Remove the shift cable from the transmission.
  28.  
  29. Remove bolt and screw holding the heat shield to the transmission.
  30.  
  31. Remove the heat shield from the transmission.
  32.  
  33. Disconnect 13-pin plug connector. Turn bayonet lock of guide bushing counterclockwise.
  34.  
  35. Remove the 13-pin connector from the transmission.
  36.  
  37. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  38.  
  39. Disconnect the transmission vent hose from the transmission.
  40.  
  41. Support rear of engine with safety stand or jack.
  42.  
  43. Raise transmission slightly with service jack to relieve load on crossmember and supports.

    Click image to see an enlarged view

    Fig. Rear crossmember-NAG1

  44.  
  45. Remove bolts securing rear support and cushion to transmission crossmember.

    Click image to see an enlarged view

    Fig. Transmission-to-oil pan bolts-NAG1

  46.  
  47. Remove the bolts holding the engine oil pan to the transmission.
  48.  
  49. Remove all remaining bolts holding the engine to the transmission.
  50.  
  51. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  52.  
  53. Hold torque converter in place during transmission removal.
  54.  
  55. Lower transmission and remove assembly from under the vehicle.
  56.  
  57. To remove torque converter, carefully slide torque converter out of the transmission.
  58.  

To install:

  1. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation.
  2.  
  3. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
  4.  
  5. Lubricate oil pump seal lip with transmission fluid.
  6.  
  7. Place torque converter in position in transmission.
    WARNING
    Do not damage oil pump seal or converter hub while inserting torque converter into the front of the transmission.

  8.  
  9. Align torque converter to oil pump seal opening.
  10.  
  11. Insert torque converter hub into oil pump.
  12.  
  13. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears.

    Click image to see an enlarged view

    Fig. Check torque converter seating

  14.  
  15. Check converter seating with a scale and straight-edge at -A-. Surface of converter lugs should be at least 1
  16.  
  17. mm ( 3 / 4 in.) to rear of straight-edge when converter is fully seated.
  18.  
  19. If necessary, temporarily secure converter with C-clamp attached to the converter housing.
  20.  
  21. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
  22.  
  23. Apply a light coating of Mopar° High Temp Grease, or equivalent, to the torque converter hub pocket in the rear pocket of the engine-s crankshaft.
  24.  
  25. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
  26.  
  27. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
  28.  
  29. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
  30.  
  31. Install two bolts to attach the transmission to the engine.
  32.  
  33. Install remaining torque converter housing to engine bolts. Tighten to 29 ft. lbs. (39 Nm).
  34.  
  35. Install rear transmission crossmember. Tighten crossmember to frame bolts to 50 ft. lbs. (68 Nm).
  36.  
  37. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  38.  
  39. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 35 ft. lbs. (47 Nm).
  40.  
  41. Remove engine support fixture.
  42.  
  43. Install the transmission to engine oil pan bolts. Tighten to 29 ft. lbs. (39 Nm).
  44.  
  45. Connect the gearshift cable to the transmission manual shift lever.
  46.  
  47. Check O-ring on plug connector, and replace if necessary.
  48.  
  49. Install the plug connector into the guide bushing. Turn bayonet lock of guide bushing clockwise to connect plug connector.
  50.  
  51. Position the heat shield onto the transmission housing and install the screw and bolt to hold the shield in place.
    WARNING
    It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

  52.  
  53. Install all torque converter-to-driveplate bolts by hand.
  54.  
  55. Verify that the torque converter is pulled flush to the driveplate. Tighten bolts to 31 ft. lbs. (42 Nm).
  56.  
  57. Install the torque converter bolt access cover onto the transmission. Install the access cover bolt and tighten to 96 inch lbs. (11 Nm).
  58.  
  59. Install starter motor.
  60.  
  61. Connect the cooler line fittings and cooler lines to the transmission.
    NOTE
    Inspect the fill tube grommet to determine if the grommet is new or used. If a new fill tube grommet is in the transmission case, pierce the center of the grommet with a ballpoint pen, or similar instrument, to prepare the grommet for the fill tube installation.

  62.  
  63. Install transmission fill tube.
  64.  
  65. Install exhaust components.
  66.  
  67. Align and connect the driveshaft.
  68.  
  69. Adjust gearshift cable if necessary.
  70.  
  71. Lower vehicle.
  72.  
  73. Connect negative battery cable.
  74.  
  75. Fill the transmission with the appropriate transmission fluid.
  76.  
  77. Verify proper operation.
  78.  

 
label.common.footer.alt.autozoneLogo