Chrysler Full-Size Trucks 1989-1996 Repair Guide

Transmission Assembly

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REMOVAL & INSTALLATION



Pick-Up and Ramcharger
  1. Remove the transmission and converter as an assembly; otherwise the converter drive plate pump bushing and oil seal will be damaged. The drive plate will not support a load. Therefore, none of the weight of transmission should be allowed to rest on the plate during removal.
  2.  
  3. Disconnect the negative battery cable. Remove the engine cover. Raise and safely support the vehicle.
  4.  
  5. Remove engine to transmission struts, if necessary. You may have to drop the exhaust system on some models.
  6.  
  7. Remove the starter. Remove wire from the neutral starting switch and converter solenoid (if equipped).
  8.  
  9. Remove the gearshift cable or rod from the transmission and the lever.
  10.  
  11. Disconnect the throttle rod from left side of transmission. Disconnect the distance sensor and speedometer.
  12.  
  13. Drain the transmission fluid and reinstall the pan. Disconnect the oil cooler lines at transmission and remove the oil filler tube. Disconnect the speedometer cable.
  14.  
  15. Remove the converter front cover. Mark the converter and flexplate to converter mounting bolts/nuts. Turn the engine in a clockwise direction to gain access to the bolts. Mark for reference and remove the driveshaft.
  16.  
  17. Install engine support fixture or position a jack to hold up the rear of the engine. Care should be taken not to place strain on the radiator hoses, etc. Watch the fan-to-radiator clearance.
  18.  
  19. Position a suitable transmission jack under the transmission. Raise the transmission slightly with the jack to relieve load and remove support bracket or crossmember. Remove all of the bell housing bolts and carefully work transmission and converter rearward off engine dowels and disengage converter hub from end of crankshaft.
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WARNING
Attach a small C-clamp to edge of bell housing to hold converter in place during transmission removal; otherwise the front pump bushing might be damaged. Install transmission and converter as an assembly. The drive plate will not support a load. Do not allow the weight of transmission to rest on the plate during installation.

  1. Using a jack, position transmission and converter assembly in alignment with engine.
  2.  
  3. Rotate converter so mark on converter (made during removal) will align with the mark on the flexplate. Carefully work the transmission assembly forward over engine block dowels with converter hub entering the crankshaft opening and the flexplate to converter mounts lined up.
  4.  
  5. Install converter housing to engine bolts and tighten them.
  6.  
  7. Install the converter to flexplate bolts.
  8.  
  9. Install the rear crossmember and connect the rear transmission mount if loosened. Install the driveshaft.
  10.  
  11. Connect oil cooler lines, install oil filler tube and connect the speedometer and distance sensor.
  12.  
  13. Connect gearshift cable or rod and torque shaft assembly to the transmission case and to the lever.
  14.  
  15. Connect throttle rod to the lever at left side of transmission bell housing.
  16.  
  17. Connect wire to back-up and neutral staring switch. Connect the converter solenoid (if equipped).
  18.  
  19. Install cover plate in front of the converter assembly. Install the starter motor and engine struts.
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  21. Lower the vehicle and refill transmission with fluid.
  22.  
  23. Adjust linkage.
  24.  

Dakota

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support safely. Drain the transmission and transfer case, if equipped.
  4.  
  5. Remove the exhaust crossover pipe.
  6.  
  7. Remove the skid plates, if equipped.
  8.  
  9. Matchmark and remove the driveshaft(s).
  10.  
  11. Disconnect the distance sensor, if equipped and the speedometer cable.
  12.  
  13. If equipped with 4WD, disconnect all linkage, electrical connectors and vacuum lines from the transfer case. Using a suitable jack, support the transfer case, unbolt the transfer case from the transmission and slide it backwards to remove it from the vehicle.
  14.  
  15. Remove the engine to transmission struts.
  16.  
  17. Remove the starter and the fluid cooler lines bracket.
  18.  
  19. Remove the torque converter inspection cover.
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  21. Matchmark the converter to the flex plate. Remove the torque converter bolts.
  22.  
  23. Disconnect the wires to the neutral safety switch and lock-up solenoid, if equipped.
  24.  
  25. Disconnect and plug the oil cooler lines from the transmission.
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  27. Disconnect the gearshift rod and torque shaft assembly from the transmission.
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  29. Disconnect the throttle rod from the lever.
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  31. Unbolt the oil filler tube brace and lift the oil filler tube out of its bore.
  32.  
  33. Install an appropriate engine support fixture to hold the engine in place when the transmission is out of the vehicle.
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  35. Raise the transmission slightly using a suitable transmission jack.
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  37. Remove the transmission crossmember.
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  39. Remove the oil filter, if necessary. Remove all bell housing bolts and remove the transmission from the vehicle.
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To install:
  1. Install the transmission securely on the transmission jack. Rotate the converter so it will align with the positioning of the flex plate.
  2.  
  3. Apply a coating of high temperature grease to the torque converter pilot hub.
  4.  
  5. Raise the transmission into place and push it forward until the dowels engage and the bell housing is flush with the block.
  6.  
  7. Install the oil filler tube. Install the bell housing bolts and tighten to 30 ft. lbs. (41 Nm). Install the oil filter, if it was removed.
  8.  
  9. Install the transmission crossmember. Remove the engine support fixture and the transmission jack.
  10.  
  11. install the torque converter bolts and tighten to 23 ft. lbs. (31 Nm).
  12.  
  13. Connect the oil cooler lines.
  14.  
  15. Connect the throttle rod to the lever and adjust if necessary.
  16.  
  17. Connect the gearshift rod and torque shaft assembly to the transmission and adjust if necessary.
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  19. Connect the wires to the neutral safety switch an lockup solenoid, if equipped. Make sure all wires are routed correctly and clipped in place.
  20.  
  21. Install the torque converter inspection cover, starter and transmission struts.
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  23. Install the transfer case, if equipped.
  24.  
  25. Connect the distance sensor, if equipped.
  26.  
  27. Connect the speedometer cable.
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  29. Install the driveshaft(s).
  30.  
  31. Install exhaust parts that were removed in order to remove the transmission.
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  33. Fill the transfer case, if equipped. Lower the vehicle.
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  35. Connect the negative battery cable.
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  37. Fill the transmission with the proper amount of ATF+3®II.
  38.  
  39. Road test the vehicle, check for leaks and recheck the fluid level.
  40.  

 
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