Cherokee, Grand Cherokee, 1999-2005

Transmission Removal & Installation

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  1. Shift transmission into first or third gear.
  2.  
  3. Raise and support vehicle on suitable safety stands.
  4.  
  5. Disconnect necessary exhaust system components.
  6.  
  7. Remove skid plate, if equipped.
  8.  
  9. Remove slave cylinder from clutch housing.
  10.  
  11. Mark rear propeller shaft and rear axle yokes for installation alignment
  12.  
  13. Mark front propeller shaft, axle, and transfer case yokes for installation alignment, if equipped.
  14.  
  15. Remove propeller shaft(s)
  16.  
  17. Unclip wire harnesses from transmission and transfer case, if equipped.
  18.  
  19. Disconnect transfer case vent hose, if equipped.
  20.  
  21. Disengage any wire connectors attached to transmission or transfer case, if equipped, components.
  22.  
  23. Support transfer case, if equipped, with transmission jack.
  24.  
  25. Secure transfer case, if equipped, to jack with safety chains.
  26.  
  27. Disconnect transfer case shift linkage at transfer case, if equipped.
  28.  
  29. Remove nuts attaching transfer case to transmission, if equipped.
  30.  
  31. Remove transfer case, if equipped.
  32.  
  33. Remove crankshaft position sensor.
    CAUTION
    It is important that the crankshaft position sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations.



    Click image to see an enlarged view

    Fig. Crankshaft position sensor for the 2.5L engine



    Click image to see an enlarged view

    Fig. Crankshaft position sensor for the 4.0L engine

  34.  
  35. Support engine with adjustable jack stand. Position wood block between jack and oil pan to avoid damaging pan.
  36.  
  37. Support transmission with transmission jack.
  38.  
  39. Secure transmission to jack with safety chains.
  40.  
  41. Disconnect rear cushion and bracket from transmission.
  42.  
  43. Remove rear crossmember.
  44.  
  45. Disconnect transmission shift lever as follows:
  46.  
  47. Lower transmission - transfer case assembly approximately 7 to 8 cm (3 in.) for access to shift lever.
  48.  
  49. Reach up and around transmission case and unseat shift lever dust boot from transmission shift tower Move boot upward on shift lever for access to retainer that secures lever in shift tower.
  50.  
  51. Reach up and around transmission case and press shift lever retainer downward with finger pressure. Turn retainer counterclockwise to release it.
  52.  
  53. Lift lever and retainer out of shift tower Do not remove the shift lever from the floor console shifter boots. Leave the lever in place for transmission installation.
  54.  
  55. Remove clutch housing brace rod.
  56.  
  57. Remove clutch housing-to-engine bolts.
  58.  
  59. Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle.
  60.  
  61. Remove clutch release bearing, release fork, and retainer clip.
  62.  
  63. Remove clutch housing from transmission
  64.  

To install:

  1. Install clutch housing on transmission. Tighten housing bolts to 27 ft. lbs.(37 Nm).
  2.  
  3. Lubricate contact surfaces of release fork pivot ball stud and release fork with high temp grease.
  4.  
  5. Install release bearing, fork, and retainer clip.
  6.  
  7. Position and secure transmission on transmission jack.
  8.  
  9. Lightly lubricate pilot bearing and transmission input shaft splines with Mopar® high temp grease.
  10.  
  11. Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place.
  12.  
  13. Install and tighten clutch housing-to-engine bolts to 28 ft. lbs.(38 Nm) Be sure the housing is properly seated on engine block before tightening bolts.
  14.  
  15. Install clutch housing brace rod.
  16.  
  17. Lower transmission approximately 7 to 8 cm (3 in.) for access to shift tower. Be sure transmission is in first or third gear.
  18.  
  19. Reach up and around transmission and insert shift lever in shift tower. Press lever retainer downward and turn it clockwise to lock it in place. Then install lever dust boot on shift tower.
  20.  
  21. Install rear crossmember. Tighten crossmember-to-frame bolts to 31 ft. lbs.(41 Nm).
  22.  
  23. Install fasteners to hold rear cushion and bracket to transmission. Then tighten transmission-to-rear support bolts/nuts to 33 ft. lbs. (45 Nm).
  24.  
  25. Remove support stands from engine and transmission. Install and connect crankshaft position sensor.
  26.  
  27. Position transfer case on transmission jack, if equipped. Secure transfer case to jack with safety chains, if equipped.
  28.  
  29. Raise transfer case, if equipped, and align transfer case input shaft to the transmission output shaft.
  30.  
  31. Slide transfer case forward until case is seated on transmission, if necessary. Install nuts to attach transfer case to transmission, if equipped. Tighten transfer case-to-transmission nuts to 26 ft. lbs. (35 Nm).
  32.  
  33. Connect transfer case shift linkage at transfer case, if equipped.
  34.  
  35. Connect transfer case vent hose, if equipped.
  36.  
  37. Secure wire harnesses in clips/tie straps on transmission and transfer case, if equipped.
  38.  
  39. Engage wire connectors attached to all necessary transmission or transfer case, if equipped, components.
  40.  
  41. Install rear propeller shaft slip yoke to transmission or transfer case, if equipped, output shaft.
  42.  
  43. Align marks on rear propeller shaft and rear axle yokes.
  44.  
  45. Install and tighten propeller shaft U-joint clamp bolts to 170 in. lbs. (19 Nm).
  46.  
  47. Align marks on front propeller shaft, axle, and transfer case yokes, if equipped.
  48.  
  49. Install and tighten propeller shaft U - joint clamp bolts to 170 in. lbs. (19 Nm) .
  50.  
  51. Install slave cylinder in clutch housing.
  52.  
  53. Install skid plate, if equipped. Tighten bolts to 31 ft. lbs. (42 Nm). Tighten stud nuts to 150 in. lbs. (17 Nm).
  54.  
  55. Fill transmission and transfer case, if equipped, with recommended lubricants.
  56.  
  57. Lower vehicle.
  58.  

Exc. NV3550



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Place the transmission in first or third gear.
  4.  
  5. Drain the fluid from the transmission.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipe
     
    Skid plate
     
    Clutch slave cylinder
     
    Rear propeller shaft
     
    Front propeller shaft, if equipped
     
    Wire harness from the transmission and transfer case, if equipped
     
    Transfer case shift linkage, if equipped
     
    Transfer case, if equipped
     
    Crankcase Position (CKP) sensor
     
    Rear cushion and transmission bracket after supporting the engine and transmission
     
    Rear crossmember
     
    Transmission shift lever
     
    Clutch housing brace rod
     
    Transmission
     

  8.  

To install:

  1. Install or connect the following:

    Transmission. Tighten the 3 / 8 inch bolts to 27 ft. lbs. (37 Nm), the 7 / 16 inch bolts to 43 ft. lbs. (58 Nm), and the 12mm bolts to 55 ft. lbs. (75 Nm).
     
    Shift lever
     
    Rear crossmember. Torque the bolts to 31 ft. lbs. (41 Nm).
     
    Rear cushion and bracket. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    CKP sensor
     
    Transfer case, if equipped. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Transfer case shift linkage, if equipped.
     
    Wire harness to the transmission.
     
    Front driveshaft and transfer case, if equipped. Torque the bolts to 12 ft. lbs. (19 Nm).
     
    Rear driveshaft. Torque the bolts to 12 ft. lbs. (19 Nm).
     
    Clutch slave cylinder.
     
    Skid plate. Torque the bolts to 31 ft. lbs. (42 Nm).
     
    Exhaust front pipe.
     
    Negative battery cable.
     

  2.  
  3. Fill the transmission with the proper fluid.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

Nv3550



  1. Shift transmission into first or third gear.
  2.  
  3. Remove the floor console and shift boot as necessary to access the bottom of the shift lever at the shift tower attachment.
  4.  
  5. Install nuts on two M6X1.0 bolts and thread the bolts into the threaded holes at the base of the shift lever.
  6.  
  7. Tighten the nuts equally until the shift lever loosens on the shift tower stub shaft.
  8.  
  9. Remove the shift lever from the shift tower.
  10.  
  11. Raise and support vehicle on suitable safety stands.
  12.  
  13. Support engine with adjustable jack stand. Position wood block between jack and oil pan to avoid damaging pan.
  14.  
  15. Remove crossmember/skid plate.
  16.  
  17. Disconnect necessary exhaust system components.
  18.  
  19. Remove skid plate, if equipped.
  20.  
  21. Remove slave cylinder from clutch housing.
  22.  
  23. Mark rear propeller shaft and rear axle yokes for installation alignment
  24.  
  25. Mark front propeller shaft, axle, and transfer case yokes for installation alignment, if equipped.
  26.  
  27. Remove propeller shaft(s)
  28.  
  29. Unclip wire harnesses from transmission and transfer case, if equipped.
  30.  
  31. Disconnect transfer case vent hose, if equipped.
  32.  
  33. Disengage any wire connectors attached to transmission or transfer case, if equipped, components.
  34.  
  35. Support transfer case, if equipped, with transmission jack.
  36.  
  37. Secure transfer case, if equipped, to jack with safety chains.
  38.  
  39. Disconnect transfer case shift linkage at transfer case, if equipped.
  40.  
  41. Remove nuts attaching transfer case to transmission, if equipped.
  42.  
  43. Remove transfer case, if equipped.
  44.  
  45. Remove crankshaft position sensor.
    CAUTION
    It is important that the crankshaft position sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations. Support engine with adjustable jack stand. Position wood block between jack and oil pan to avoid damaging pan.

  46.  
  47. Support transmission with transmission jack.
  48.  
  49. Secure transmission to jack with safety chains.
  50.  
  51. Disconnect rear cushion and bracket from transmission.
  52.  
  53. Remove rear crossmember.
  54.  
  55. Remove clutch housing-to-engine bolts.
  56.  
  57. Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle.
  58.  
  59. Remove clutch release bearing, release fork, and retainer clip.
  60.  
  61. Remove clutch housing from transmission
  62.  

To install:

  1. Install clutch housing on transmission. Tighten housing bolts to 34 ft. lbs. (46 Nm).
  2.  
  3. Lubricate contact surfaces of release fork pivot ball stud and release fork with high temp grease.
  4.  
  5. Install release bearing, fork, and retainer clip.
  6.  
  7. Position and secure transmission on transmission jack.
  8.  
  9. Lightly lubricate pilot bearing and transmission input shaft splines with Mopar®high temp grease.
  10.  
  11. Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place.
  12.  
  13. Install and tighten clutch housing-to-engine bolts to the appropriate torque: Be sure the housing is properly seated on engine block before tightening bolts.
  14.  
  15. Tighten 3 / 8 inch diameter bolts to 27 ft. lbs. (37 Nm)
  16.  
  17. Tighten 7 / 16 inch diameter bolts to 43 ft. lbs. (58 Nm)
  18.  
  19. Tighten M12 bolts to 55 ft. lbs. (75 Nm)
  20.  
  21. Be sure transmission is in first or third gear.
  22.  
  23. Install rear crossmember. Tighten crossmember-to-frame bolts to 31 ft. lbs. (41 Nm).
  24.  
  25. Install fasteners to hold rear cushion and bracket to transmission. Then tighten transmission-to-rear support bolts/nuts to 40 ft. lbs. (54 Nm).
  26.  
  27. Remove support stands from engine and transmission.
  28.  
  29. Install and connect crankshaft position sensor.
  30.  
  31. Position transfer case on transmission jack, if equipped.
  32.  
  33. Secure transfer case to jack with safety chains, if equipped.
  34.  
  35. Raise transfer case, if equipped, and align transfer case input shaft to the transmission output shaft.
  36.  
  37. Slide transfer case forward until case is seated on transmission, if necessary.
  38.  
  39. Install nuts to attach transfer case to transmission, if equipped. Tighten transfer case-to-transmission nuts to 26 ft. lbs. (35 Nm).
  40.  
  41. Connect transfer case shift linkage at transfer case, if equipped.
  42.  
  43. Connect transfer case vent hose, if equipped.
  44.  
  45. Secure wire harnesses in clips/tie straps on transmission and transfer case, if equipped.
  46.  
  47. Engage wire connectors attached to all necessary transmission or transfer case, if equipped, components.
  48.  
  49. Install rear propeller shaft slip yoke to transmission or transfer case, if equipped, output shaft.
  50.  
  51. Align marks on rear propeller shaft and rear axle yokes
  52.  
  53. Install and tighten propeller shaft U - joint clamp bolts to 170 inch lbs. (19 Nm).
  54.  
  55. Align marks on front propeller shaft, axle, and transfer case yokes, if equipped. Install and tighten propeller shaft U - joint clamp bolts to 170 inch lbs. (19 Nm).
  56.  
  57. Install slave cylinder in clutch housing.
  58.  
  59. Install skid plate, if equipped. Tighten bolts to 31 ft. lbs. (42 Nm). Tighten stud nuts to 150 inch lbs. (17 Nm).
  60.  
  61. Fill transmission and transfer case, if equipped, with recommended lubricants.
  62.  
  63. Lower vehicle.
  64.  
  65. Install nuts on two M6X1.0 bolts and thread the bolts into the threaded holes at the base of the shift lever.
  66.  
  67. Tighten the nuts equally until the shift lever will slide over the shift tower stub shaft.
  68.  
  69. Install the floor console and shift boot.
  70.  

 
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