Chrysler Full-Size Trucks 1989-1996 Repair Guide

Transmission

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REMOVAL & INSTALLATION



4-Speed 2WD Pick-Up and Ramcharger
  1. Disconnect the negative battery cable. Remove the engine cover. Remove the gear shift lever and shift unit. Raise and support the vehicle. Drain the transmission fluid.
  2.  
  3. Mark the rear driveshaft yoke to differential for correct installation reference. Disconnect the rear universal joint and remove the driveshaft.
  4.  
  5. Disconnect the speedometer cable and back-up light switch electrical harness.
  6.  
  7. Support the rear of the engine. Remove the rear mount to crossmember bolts/nuts. Raise the rear of the engine slightly. Take care when raising the engine so nothing in the front of the engine, hoses lines, fan to radiator is strained or damaged.
  8.  
  9. Remove the rear transmission support crossmember. Position a suitable support jack under he transmission. Remove transmission to clutch bell housing retaining bolts and pull transmission rearward until drive pinion clears clutch, then remove transmission.
  10.  

To install:
  1. Place a small amount of Mopar® Multi-purpose Grease No. 4318063, or equivalent into clutch pilot bushing and on the clutch release bearing sleeve. Do not get any grease on the flywheel face. Do not lubricate the end of the transmission input shaft, clutch disc splines, or clutch release levers.
  2.  
  3. Align clutch disc and backing plate with a spare drive pinion shaft or clutch aligning tool.
  4.  
  5. Raise the transmission into position. Slide the transmission forward until the input shaft is aligned with and starts to enter the clutch disc splines. With the transmission in gear, turn the splines until they are aligned then push the transmission in until it mates to the bell housing.
  6.  
  7. Install transmission to bell housing bolts, tightening to 50 ft. lbs. (68 Nm). Install the crossmember and tighten the mounting bolts to 30 ft. lbs. (41 Nm). Attach the rear transmission mount to the crossmember and tighten to 50 ft. lbs. (68 Nm).
  8.  
  9. Install gear shift unit and tighten the mounting bolts to 24 ft. lbs. (33 Nm). Install and adjust the shift linkage.
  10.  
  11. Install the driveshaft. Connect the speedometer cable and back-up light.
  12.  
  13. Install the transmission drain plug and fill the transmission with lubrication.
  14.  
  15. Install the shift lever and engine cover. Lower the vehicle. Connect the battery cable.
  16.  

4-Speed 4WD Pick-Up and Ramcharger

  1. Raise and support the truck.
  2.  
  3. Remove the skid plate, if any. Drain lubricant from the transmission and transfer case.
  4.  
  5. Disconnect the speedometer cable.
  6.  
  7. Disconnect and match-mark the front and rear driveshafts. Suspend each shaft from a convenient place; do not allow them to hang free.
  8.  
  9. Disconnect the shift rods at the transfer case. Remove the shift lever retainer by pressing down and turning it counterclockwise. Remove the shift lever springs and washers.
  10.  
  11. Remove the rear driveshaft. Matchmark the driveshaft and rear U-joints before removing the driveshaft.
  12.  
  13. Support the transfer case.
  14.  
  15. Remove the extension-to-transfer case mounting bolts.
  16.  
  17. Move the transfer case rearward to disengage the front input shaft spline.
  18.  
  19. Lower and remove the transfer case.
  20.  
  21. Disconnect the back-up light switch.
  22.  
  23. Support the engine.
  24.  
  25. Support the transmission.
  26.  
  27. Remove the transmission crossmember.
  28.  
  29. Remove the transmission-to-clutch housing bolts.
  30.  
  31. Slide the transmission rearward until the mainshaft clears the clutch disc.
  32.  
  33. Lower and remove the transmission.
  34.  
  35. The transmission pilot bushing in the end of the crankshaft requires high-temperature grease. Multi-purpose grease should be used. Do not lubricate the end of the mainshaft, clutch splines, or clutch release levers.
  36.  
  37. Raise and position the transmission.
  38.  
  39. Slide the transmission forward until the mainshaft enters the clutch disc, then push it all the way forward.
  40.  
  41. Install the transmission-to-clutch housing bolts. Tighten the bolts to 50 ft. lbs. (68 Nm).
  42.  
  43. Install the transmission crossmember.
  44.  
  45. Connect the back-up light switch.
  46.  
  47. Raise and position the transfer case.
  48.  
  49. Move the transfer case rearward to disengage the front input shaft spline.
  50.  
  51. Install the extension-to-transfer case mounting bolts. Tighten the bolts to 50 ft. lbs. (68 Nm).
  52.  
  53. Install the transmission crossmember.
  54.  
  55. Connect the back-up light switch.
  56.  
  57. Raise and position the transfer case.
  58.  
  59. Move the transfer case rearward to disengage the front input shaft spline.
  60.  
  61. Install the extension-to-transfer case mounting bolts. Tighten the bolts to 50 ft. lbs. (68 Nm).
  62.  
  63. Install the rear driveshaft.
  64.  
  65. Connect the shift rods at the transfer case. Install the shift lever retainer by pressing down and turning it clockwise. Install the shift lever springs and washers.
  66.  
  67. Connect the front driveshafts.
  68.  
  69. Connect the speedometer cable.
  70.  
  71. Install the skid plate, if any. Fill the transmission and transfer case.
  72.  
  73. Lower the truck.
  74.  

Pick-Up and Ramcharger With the NP2500 Transmission

  1. Disconnect the negative battery cable. Remove the engine cover. Remove the upper shift lever. Raise and support the vehicle. Drain the transmission fluid.
  2.  
  3. Mark the rear driveshaft yoke to differential for correct installation reference. Disconnect the rear universal joint and remove the driveshaft.
  4.  
  5. If necessary, remove the exhaust system Y-pipe for clearance.
  6.  
  7. Disconnect the back-up light switch and distance sensor electrical harness. Separate the sensor from the speedometer adapter. Remove the speedometer components.
  8.  
  9. Support the rear of the engine. Remove the rear mount to crossmember bolts/nuts. Raise the rear of the engine slightly. Take care when raising the engine so nothing in the front of the engine, hoses lines, fan to radiator is strained or damaged.
  10.  
  11. Remove the rear transmission support crossmember. Position a suitable support jack under the transmission. Remove transmission to clutch bell housing retaining bolts and pull transmission rearward until drive pinion clears clutch, then remove transmission.
  12.  

To install:
  1. Place a small amount of Mopar® Multi-purpose Grease No. 4318-63, or equivalent into clutch pilot bushing and on the clutch release bearing sleeve. Do not get any grease on the flywheel face. Do not lubricate the end of the transmission input shaft, clutch disc splines, or clutch release levers.
  2.  
  3. Align clutch disc and backing plate with a spare drive pinion shaft or clutch aligning tool.
  4.  
  5. Raise the transmission into position. Slide the transmission forward until the input shaft is aligned with and starts to enter the clutch disc splines. With the transmission in gear, turn the splines until they are aligned then push the transmission in until it mates to the bell housing.
  6.  
  7. Install transmission to bell housing bolts. Install the crossmember. Attach the rear transmission mount to the crossmember.
  8.  
  9. Install the driveshaft. Connect the speedometer components. Install the distance sensor. Connect the back-up light.
  10.  
  11. Install the transmission drain plug and fill the transmission with lubricant.
  12.  
  13. Install the upper shift lever and engine cover. Lower the vehicle. Connect the battery cable.
  14.  

2WD Pick-Up With Getrag G-360 Transmission

See Figures 1, 2, 3, 4, 5, 6, 7 and 8

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the screws attaching the shift lever upper boot to the metal plate on the lower boot. Slide the boot upward on the lever.
  4.  
  5. Remove the screws attaching the lower boot and plate assembly to the floor pan.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the shift lever alignment bolts as shown from the Getrag G-360 transmission

  1. Remove the shift lever extension by un-threading it from the shift lever.
  2.  
  3. Slide the lower boot and plate upward and off the shift lever.
  4.  
  5. Remove the transmission shift tower boot. Loosen the clamp securing the boot to the shift tower. Slide the boot up and off the shift lever and tower.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the snapring from the Getrag G-360 shifter

  1. Remove the small shoulder-type alignment bolts at each side of the shift tower.
  2.  
  3. Remove the snapring securing the shift lever in the shift tower.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Shift lever alignment slots on the Getrag transmission

  1. Remove the shift lever. If the lever doesn't come out readily, press the lever downward and quickly release it two or three times. Pressure from the spring under the lever should push it out of the housing.
  2.  
  3. Raise the vehicle and support it safely.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Mark the driveshaft U-joints and axle yokes as shown for an assembly alignment reference



Click image to see an enlarged view

Fig. Fig. 5: Disengage the connectors shown from the G-360 transmission

  1. Mark the propeller shaft U-joints and axle yokes for assembly alignment reference.
  2.  
  3. Remove the propeller shaft. Remove the clamp strap bolts at the front of the shaft first. Remove the center bearing bracket bolts and support the shaft with a jackstand. Remove the rear clamp strap bolts and remove the shaft.
  4.  
  5. Unplug the distance sensor and back-up light switch connectors.
  6.  
  7. Spread the clamps securing the switch wires to the transmission top cover and remove the wires from the clamps. Move the wires aside.
  8.  
  9. Remove the bolts attaching the transmission rear mount to the crossmember.
  10.  
  11. Support the transmission with a suitable jack. Use a safety chain to secure the transmission to the jack.
  12.  



Click image to see an enlarged view

Fig. Fig. 6: Loosen the slave cylinder nuts to reduce pressure on the release lever and bearing



Click image to see an enlarged view

Fig. Fig. 7: Use a reliable method (as shown) to support the engine during transmission removal

  1. Remove the screws attaching the fuel line clamps to the driver side frame rail. There are three of them.
  2.  
  3. Remove the left and right crossmember-to-frame braces, then remove the crossmember.
  4.  
  5. Remove the clutch slave cylinder shield.
  6.  
  7. Loosen the clutch slave cylinder attaching nuts until the cylinder piston rod is clear of the release lever. The cylinder does not have to be completely removed.
  8.  
  9. Remove the bolts attaching the transmission to the clutch housing and remove the transmission. Rock the transmission slightly to help free the input shaft from the clutch disc and release bearing. Support the engine with a wood block and adjustable jackstand.
  10.  

To install:
  1. Apply a light coating of Mopar® high temperature bearing grease to the transmission input shaft and release bearing slide surface of the front bearing retainer. Apply a light coating of grease to the bore of the release bearing.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Lubricate the input shaft at the locations indicated when installing the transmission

  1. Align the transmission and clutch housing. Move the transmission forward and start the input shaft into the release bearing and clutch disc hub.
  2.  
  3. Move the transmission forward and seat it against the housing.
  4.  
  5. Install and tighten the transmission mounting bolts to 50 ft. lbs. (68 Nm).
  6.  
  7. Install the rear crossmember and crossmember brackets. Start all crossmember bolts before tightening to 50 ft. lbs. (68 Nm).
  8.  
  9. Remove the transmission jack.
  10.  
  11. Install the fuel line clamps back onto the driver side frame rail.
  12.  
  13. Align the clutch slave cylinder in the housing and tighten the cylinder attaching nuts. Install the clutch slave cylinder shield.
  14.  
  15. Secure the back-up light and distance sensor wires into the clips on top of the transmission. Route the wires across the top of the t transmission and reconnect the switch and sensor connectors.
  16.  
  17. Align and install the propeller shaft. Install the shaft front U-joint first. Secure the center bearing bracket to frame bracket, then install the shaft rear U-joint in the axle yoke. Tighten the U-joint clamp bolts to 14 ft. lbs. (19 Nm) and the center bearing bracket bolts to 50 ft. lbs. (68 Nm).
  18.  
  19. Lower the vehicle. Lubricate the shift leverball and collar with Mopar® all-purpose grease. Align the notches in the shift lever ball and collar and insert the shift lever in the shift tower. Press the shift lever downward and install the snapring. Tighten the shift lever alignment bolts completely.
  20.  
  21. Install the lower boot and plate assembly. Thread the shift lever extension onto the shift lever, then install the upper boot and plate. Install the shift knob and connect the negative battery cable.
  22.  

4WD Pick-Up With Getrag G-360 Transmission

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the screws attaching the shift lever upper boot to the metal plate on the lower boot. Slide the boot upward on the lever.
  4.  
  5. Remove the screws attaching the lower boot and plate assembly to the floor pan.
  6.  
  7. Remove the shift lever extension by un-threading it from the shift lever.
  8.  
  9. Slide the lower boot and plat upward and off the shift lever.
  10.  
  11. Remove the transmission shift tower boot. Loosen the clamp securing the boot to the shift tower. Slide the boot up and off the shift lever and tower.
  12.  
  13. Remove the small should-type alignment bolts at each side of the shift tower.
  14.  
  15. Remove the snapring securing the shift lever in the shift tower.
  16.  
  17. Remove the shift lever. If the lever doesn't come out readily, press the lever downward and quickly release it two or three times. Pressure from the spring under the lever should push it out of the housing.
  18.  
  19. Raise the vehicle and support it safely.
  20.  
  21. Mark the front and rear propeller shafts for installation reference, then disconnect and remove both shafts.
  22.  
  23. Remove the transfer case skid plate and crossmember.
  24.  
  25. Disconnect the distance sensor and back-up light with connectors.
  26.  
  27. Disconnect the transfer case shift lever from the transfer case.
  28.  
  29. Support the transmission with an adjustable jackstand and support the transfer case with a transmission jack.
  30.  
  31. Remove the nuts attaching the transfer case to the transmission adapter. Lower the transfer case and move it from under the vehicle.
  32.  
  33. Move the adjustable jackstand from under the transmission and position it to support the engine.
  34.  
  35. Spread the clamps securing the switch wires to the transmission top cover and remove the wires from the clamps. Move the wires aside.
  36.  
  37. Remove the bolts attaching the transmission rear mount to the crossmember.
  38.  
  39. Support the transmission with a suitable jack. Use a safety chain to secure the transmission to the jack.
  40.  
  41. Remove the screws attaching the fuel line clamps to the driver side frame rail. There are three of them.
  42.  
  43. Remove the left and right crossmember-to-frame braces, then remove the crossmember.
  44.  
  45. Remove the clutch slave cylinder shield.
  46.  
  47. Loosen the clutch slave cylinder attaching nuts until the cylinder piston rod is clear of the release lever. The cylinder does not have to be completely removed.
  48.  
  49. Remove the bolts attaching the transmission to the clutch housing and remove the transmission. Rock the transmission slightly to help free the input shaft from the clutch disc and release bearing. Support the engine with a wood block and adjustable jackstand.
  50.  

To install:
  1. Apply a light coating of Mopar® high temperature bearing grease to the transmission input shaft and release bearing slide surface of the front bearing retainer. Apply a light coating of grease to the bore of the release bearing.
  2.  
  3. Align the transmission and clutch housing. Move the transmission forward and start the input shaft into the release bearing and clutch disc hub.
  4.  
  5. Move the transmission forward and seat it against the housing.
  6.  
  7. Install and tighten the transmission mounting bolts to 50 ft. lbs. (68 Nm).
  8.  
  9. Install the rear crossmember and crossmember brackets. Start all crossmember bolts before tightening to 50 ft. lbs. (68 Nm).
  10.  
  11. Remove the transmission jack.
  12.  
  13. Install the fuel line clamps back onto the driver side frame rail.
  14.  
  15. Align the clutch slave cylinder in the housing and tighten the cylinder attaching nuts. Install the clutch slave cylinder shield.
  16.  
  17. Secure the back-up light and distance sensor wires into the clips on top of the transmission. Route the wires across the top of the transmission and reconnect the switch and sensor connectors.
  18.  
  19. Install the gasket and transfer case on the transmission adapter. Tighten the transfer case attaching nuts to 35 ft. lbs. (47 Nm).
  20.  
  21. Check the transmission and transfer case lubricant levels and top off, if necessary. Connect the transfer case shift lever to the transfer case.
  22.  
  23. Align and install the propeller shaft. Install the shaft front U-joint first. Secure the center bearing bracket to frame bracket, then install the shaft rear U-joint in the axle yoke. Tighten the U-joint clamp bolts to 14 ft. lbs. (19 Nm) and the center bearing bracket bolts to 50 ft. lbs. (68 Nm).
  24.  
  25. Lower the vehicle. Lubricate the shift lever ball and collar with Mopar® all-purpose grease. Align the notches in the shift lever ball and collar and insert the shift lever in the shift tower. Install the shift lever downward and install the snapring. Tighten the shift lever alignment bolts completely.
  26.  
  27. Install the lower boot and plate assembly. Thread the shift lever extension onto the shift lever, then install the upper boot and plate. Install the shift knob and connect the negative battery cable.
  28.  

Pick-Up and Ramcharger With NV3500/4500

  1. Disconnect the negative battery cable. Remove the upper shift lever. Raise and support the vehicle. Drain the transmission fluid.
  2.  
  3. Mark the rear driveshaft yoke to differential for correct installation reference. Disconnect the rear universal joint and remove the driveshaft.
  4.  
  5. 4WD vehicles: If necessary, remove the exhaust system Y-pipe for clearance.
  6.  
  7. Disconnect the back-up light switch and distance sensor electrical harness. Separate the sensor from the speedometer adapter. Remove the speedometer components.
  8.  
  9. Support the rear of the engine. Remove the rear mount to crossmember bolts/nuts. Raise the rear of the engine slightly. Take care when raising the engine so nothing in the front of the engine, hoses lines, fan to radiator is strained or damaged.
  10.  
  11. Remove the rear transmission support crossmember. Position a suitable support jack under the transmission. Remove transmission to clutch bell housing retaining bolts and pull transmission rearward until drive pinion clears clutch, then remove transmission.
  12.  

To install:
  1. Place a small amount of Mopar® Multi-purpose Grease No. 4318-63, or equivalent onto the following components:

    Drive gear splines and the pilot bearing hub
     
    Release bearing slide surface of the front retainer
     
    Pilot bearing
     
    Release bearing bore
     
    Release fork
     
    Release fork ball stud
     
    Driveshaft slip yoke
     

  2.  


WARNING
Do not get any grease on the flywheel face. Do not lubricate the end of the transmission input shaft, clutch disc splines, or clutch release levers.

  1. Align clutch disc and backing plate with a spare drive pinion shaft or clutch aligning tool.
  2.  
  3. Raise the transmission into position. Slide the transmission forward until the input shaft is aligned with and starts to enter the clutch disc splines. With the transmission in gear, turn the splines until they are aligned then push the transmission in until it mates to the bell housing.
  4.  
  5. Install transmission to bell housing bolts. Install the crossmember. Attach the rear transmission mount to the crossmember.
  6.  
  7. Install the driveshaft. Connect the speedometer components. Install the distance sensor. Connect the back-up light.
  8.  
  9. If removed, install the exhaust system Y-pipe.
  10.  
  11. Install the transmission drain plug and fill the transmission with lubricant.
  12.  
  13. Install the upper shift lever and engine cover. Lower the vehicle. Connect the battery cable.
  14.  

Dakota

  1. Disconnect the negative battery cable.
  2.  
  3. Shift the transmission into Neutral and remove the upper shift lever.
  4.  
  5. Raise the vehicle and support safely. Remove the skid plate(s), if equipped. Drain the transmission lubricant.
  6.  
  7. Matchmark and remove the driveshaft(s).
  8.  
  9. Disconnect the wires from t he distance sensor, if equipped. Then loosen the sensor coupling and remove the sensor from the speedometer adaptor.
  10.  
  11. Disconnect the reverse light switch. Remove the transfer case, if equipped.
  12.  
  13. Install engine support fixture C-3487-A, or equivalent, to support the engine while the transmission is out of the vehicle. Raise the engine slightly with the support fixture.
  14.  
  15. Disconnect the insulator from the extension housing.
  16.  
  17. Using the proper equipment, support the transmission and remove the crossmember.
  18.  
  19. Remove the transmission to clutch housing bolts.
  20.  
  21. Slide the transmission rearward until the input shaft clears the clutch disc.
  22.  
  23. Pull the transmission completely away from the clutch housing and remove the transmission from the vehicle.
  24.  

To install:
  1. Lubricate the pilot bushing and input shaft splines very lightly with high temperature lubricant.
  2.  
  3. Mount the transmission securely on a suitable transmission jack and lift it is place until the input shaft is centered in the clutch housing opening. Roll the transmission forward until the input shaft splines fully engage with the clutch disc.
  4.  
  5. Install the transmission to clutch housing bolts. Tighten the bolts to 50 ft. lbs. (68 Nm).
  6.  
  7. Install the transmission crossmember. Remove the transmission and engine support fixtures.
  8.  
  9. Install the transfer case, if equipped and connect all linkage, electrical connectors and vacuum lines to the transfer case.
  10.  
  11. Connect the reverse light switch connector and clip all wiring to the transmission case.
  12.  
  13. Connect speedometer cable and distance sensor, if equipped.
  14.  
  15. Install the driveshaft(s).
  16.  
  17. Fill the transmission with the proper amount of 10W-30 engine oil with an API classification SG/CD. Fill the transfer case, if equipped, with the proper amount of ATF+3®II lubricant.
  18.  
  19. Apply silicone sealer to the perimeter of the shifter base and install the shifter assembly.
  20.  
  21. Install the skid plate(s), if equipped.
  22.  
  23. Connect the negative battery cable and check the transmission for proper operation.
  24.  

 
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