Chrysler RAM50/D50/Arrow 1979-1993 Repair Guide

Transmission

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REMOVAL & INSTALLATION



1979-82 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the starting motor wiring and remove the starter motor.
  6.  
  7. Remove the transmission mounting bolts from the bell housing.
  8.  
  9. Place a drain pan under the transmission oil pan, then remove the oil filler tube by pulling it up.
  10.  
  11. Jack up the vehicle and safely support it.
  12.  
  13. If necessary, loosen the oil pan bolts and tap on one corner of the pan to loosen allowing the oil to drain. Remove the pan once the fluid is drained.
  14.  
  15. Disconnect the speedometer cable from the transmission.
  16.  
  17. Seperate the exhaust pipe from the transmission.
  18.  
  19. Disconnect the throttle rod from the throttle lever at the left side of the transmission.
  20.  
  21. Remove the oil cooler tube, linkage bellcrank, control rod and bell housing cover from the transmission.
  22.  
  23. Rotate the engine clockwise with a wrench on crankshaft pulley bolt to position the bolts attaching the torque converter to the drive plate, and remove them.
  24.  
  25. Support the rear of the engine with a jack.
  26.  
  27. With the transmission support on a service jack, remove the rear engine rear support bracket.
  28.  


CAUTION
When the transmission is supported on a jack, the supporting area should be as wide as possible.

  1. Remove the remaining transmission mounting bolts from the bell housing.
  2.  
  3. Draw the transmission rearward from the engine.
  4.  
  5. Lower the jack, and take the transmission and converter assembly off from under the vehicle.
  6.  
  7. To remove the converter, carefully slide it out of the transmission.
  8.  

To install:

The transmission and converter must be installed as an assembly, otherwise the converter driveplate, pump bushing and oil seal will be damaged. The drive plate will not support a load, therefore, none of the weight of the transmission should be allowed to rest on the plate during installation.

  1. Rotate the pump rotors with tool C-3756 or equivalent until the two small holes in the handle are vertical.
  2.  
  3. Attach a small "C" clamp to the edge of the converter housing to retain the converter in place during transmission installation.
  4.  
  5. Inspect the converter drive plate for distortion or cracks, replace if necessary. Tighten the drive plate-to-crankshaft bolts to 83-90 ft. lbs. (112-122 Nm. When the drive plate replacement is necessary, make sure both the transmission dowel pins are in engine block and they are protruding far enough to hold the transmission in alignment.
  6.  
  7. Coat the converter hub hole in the crankshaft with Multi-purpose grease. Place the transmission and converter assembly on a service jack, then position the assembly under the vehicle for installation. Raise or tilt as necessary until the transmission is aligned with the engine.
  8.  
  9. Carefully work the assembly forward overt the engine block dowels with the converter hub entering the crankshaft opening.
  10.  
  11. After the transmission is into position, install the converter housing bolts and tighten to 22-30 ft. lbs. (31-40 Nm).
  12.  
  13. Install the crossmember-to-frame and lower the transmission to install mount on the extension to the crossmember.
  14.  
  15. Install the oil filler tube and speedometer cable.
  16.  
  17. Connect the throttle rod to the transmission lever.
  18.  
  19. Connect the gearshift rod and torque shaft assembly to the transmission lever and frame.
  20.  
  21. Carefully guide the sliding yoke into the extension housing and on the output shaft splines. Align the marks made at removal then connect the propeller shaft to the rear axle pinion shaft yoke.
  22.  
  23. Rotate the engine clockwise with socket wrench on the crankshaft pulley bolt, as needed to install the converter to the drive plate bolts. Tighten the bolts to 25-30 ft. lbs. (34-40 Nm).
  24.  
  25. Install the starter motor, tighten the mounting bolts to 15-22 ft. lbs. (20-29 Nm). Install the cooler line bracket.
  26.  
  27. Tighten the cooler lines to the transmission linkage.
  28.  
  29. Adjust the shift and throttle linkage.
  30.  
  31. Refill the transmission with ATF+3 type automatic transmission fluid.
  32.  

1983-89 Models See Figures 1, 2 and 3


WARNING
The transmission and the torque converter must always be connected when removed from the engine, otherwise damage to the drive plate, oil pump bushing and oil seal could be the result. The drive plate cannot support any load. Make sure that the weight of the transmission does not act on the drive plate during removal.

  1. Disconnect the negative battery cable.
  2.  
  3. It may be necessary to remove the front exhaust pipe (AW372 and KM148 transmissions), do so now. Disconnect the front exhaust pipe from the exhaust manifold and the catalytic converter.
  4.  
  5. Disconnect the kickdown linkage.
  6.  
  7. Remove the selector lever cover and the console. Remove the selector lever.
  8.  
  9. Raise and safely support the vehicle on stands.
  10.  
  11. If 4WD, remove the skid plate from below the transfer case.
  12.  
  13. Remove the shifter control linkage from the transmission. Remove the transfer shifter (if 4WD) and the transmissions shifter.
  14.  
  15. Drain the transmission fluid into a suitable container.
  16.  
  17. Disconnect the oil cooler lines and hose from the transmission. Immediately plug or cap the open lines and ports. Suspend the lines vertically to reduce leakage into the work. Disconnect the front and rear driveshafts from the transmission and transfer case.
  18.  
  19. Disconnect the speedometer cable, the back up light wiring and the four wheel drive indicator wiring if so equipped.
  20.  
  21. Remove the converter cover. Remove the torque converter to flex plate (drive plate) retaining bolts. The torque converter will have to be turned as the bolts are loosened and removed, having a friend turn the crankshaft with a large wrench is extremely helpful.
  22.  
  23. Remove the starter mounting bolts and remove the starter. If you're careful, the wiring can remain attached; use stiff wire to tie the starter to a frame rail or other solid mount. Allow it to hang from the wire (NOT the electrical wires-the stiff wire).
  24.  
  25. Support the transmission with a jack or transmission cradle. Distribute the weight of the transmission over a wide area with a piece of lumber.
  26.  
  27. Remove the rear insulator from the crossmember.
  28.  
  29. Remove the crossmember. It is heavy and bulky; a second jack can be helpful in removing it.
  30.  
  31. Remove the transfer case support (on 4WD). Remove the transmission retaining (bell housing) bolts and remove the transmission unit out of the vehicle. Slide the transmission backward and then down, the transmission needs to clear the alignment tangs.
  32.  

To install:
  1. Raise the transmission into place and install the retaining (bell housing) bolts. Install the transfer case support if so equipped.
  2.  
  3. Install the rear insulator on the crossmember.
  4.  
  5. Install the starter.
  6.  
  7. Have that friend of yours turn the engine until the flywheel (drive plate) holes line up with the torque converter holes. Install the first bolt finger tight, then have the engine turned and install the next bolt only finger tight. Continue to do this until all of the converter bolts are installed finger tight in the flywheel. Tighten the flywheel to torque converter bolts in two stages up to 25-30 ft. lbs. (35-42 Nm). If the bolts aren't tightened in stages, the flywheel may become tightened down on an angle.
  8.  
  9. Install the converter cover.
  10.  
  11. Connect the speedometer cable, backup light switch wiring and 4WD indicator wiring harness.
  12.  
  13. Connect the front and rear driveshafts to the transmission and transfer case.
  14.  
  15. Connect the oil cooler tubes and hoses from the transmission.
  16.  
  17. Install the shift control arm, cross select shaft and control rod to the transmission.
  18.  
  19. Install the skid plate if so equipped.
  20.  
  21. Lower the vehicle the ground.
  22.  
  23. Install the shifter linkage-refer to the previous procedures in this section.
  24.  
  25. Install the transfer and transmission shifter assemblies.
  26.  
  27. Connect the kickdown link.
  28.  
  29. Install the front exhaust pipe.
  30.  
  31. Install the proper amount of transmission fluid.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. After installation, refill the transmission with the approved fluid. Check that the transmission will start only in N and P positions and that the back-up lights function only in the R position, otherwise adjusted the shifter linkage.
  36.  



Click image to see an enlarged view

Fig. Fig. 1: Automatic transmission removal and installation-AW372 transmissions



Click image to see an enlarged view

Fig. Fig. 2: Automatic transmission removal and installation-KM148 transmissions



Click image to see an enlarged view

Fig. Fig. 3: Automatic transmission removal and installation, continued-KM148 transmissions

1990-93 Models See Figure 4

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and safely support the vehicle on jackstands. Chock the wheels on the ground to keep the vehicle from rolling when the driveshafts are removed.
  4.  
  5. Remove the under covers.
  6.  
  7. Remove the front exhaust pipe.
  8.  
  9. Matchmark the driveshaft to the rear differential unit and the transmission. Detach the driveshaft from the rear differential and slide the yoke out of the tail of the transmission. Have a pan handy to catch the draining transmission fluid. Try not to spill any transmission fluid because it will stain any clothing and even pavement.
  10.  
  11. Remove the transmission fluid filler tube. Dispose of the O-ring on the end of the tube (it will need to be replaced with a new on upon reassembly).
  12.  
  13. Unplug the transmission harness connector.
  14.  
  15. Loosen the speedometer cable retaining ring, then pull the cable out of the transmission.
  16.  
  17. Disconnect the transmission control rod at the transmission.
  18.  
  19. Disconnect the fluid cooler hoses from the transmission.
  20.  
  21. Disconnect the kickdown rod from the cable.
  22.  
  23. Remove the exhaust pipe mounting bracket from the right side of the transmission.
  24.  
  25. Remove the lower torque converter cover.
  26.  
  27. Remove the torque converter to flywheel bolts. Having a friend turn the engine with a large wrench is a lot of help for this procedure.
  28.  
  29. Support the transmission with a floor jack or a transmission cradle.
  30.  
  31. Remove the two mounting bolts holding the tail of the transmission to the crossmember, then remove the crossmember.
  32.  
  33. With the transmission tilted so that the rear is lowered slightly, remove the flange bolt which fastens the starter motor and bell crank bracket.
  34.  



Click image to see an enlarged view

Fig. Fig. 4: Automatic transmission removal and installation-R4AC1 transmissions

Suspend the starter motor from the body by using a piece of wire or a similar method.

  1. Disconnect the transmission assembly from the engine by pulling it slowly toward the rear of the vehicle.
  2.  

Detach so that the torque converter does not remain at the engine side.

To install:
  1. On the engine side, there are two centering locations. Make sure that the transmission mounting bolt holes are aligned with them before mounting the transmission assembly to the engine.
  2.  

The engine with the transmission assembly removed has its rear slightly raised up due to imbalance caused by such removal. Therefore, disconnect the front exhaust pipe from the catalytic converter to lower the engine.

  1. Install the bell housing-to-engine block bolts (refer to the illustration for the torque figures). While installing these bolts also install the bell crank bracket assembly and the starter motor.
  2.  
  3. Install the crossmember, then secure the rear of the transmission to the crossmember with the two mounting nuts. Tighten the rear nuts to 14-20 ft. lbs. (20-27 Nm).
  4.  
  5. Install the torque converter-to-flywheel bolts. Before installing the bolts, make sure that the torque converter paint color can be seen through the check hole in the drive plate. Have that friend of yours turn the engine until the flywheel (drive plate) holes line up (and color can be seen) with the torque converter holes. Install the first bolt finger tight, then have the engine turned and install the next bolt only finger tight. Continue to do this until all of the converter bolts are installed finger tight in the flywheel. Tighten the flywheel-to-torque converter bolts in two stages up to 33-38 ft. lbs. (46-53 Nm). If the bolts aren't tightened in stages, the flywheel may become tightened down on an angle.
  6.  
  7. Install the bell housing lower cover.
  8.  
  9. Install the exhaust pipe mounting bracket to the right side of the transmission. Tighten the mounting nuts to 14-20 ft. lbs. (20-27 Nm).
  10.  
  11. Install the transmission throttle (kickdown) lever.
  12.  
  13. Connect the transmission cooler tubes to the transmission. Make sure to install the cooler tube retainer to the transmission.
  14.  
  15. Connect the transmission control rod to the transmission. Both the kickdown and the control rod will have to be adjusted once the transmission is completely installed-refer to the procedures in this section.
  16.  
  17. Insert the speedometer cable into the transmission, then tighten the retaining ring to hold it in place.
  18.  
  19. Plug the transmission harness connectors together.
  20.  
  21. Insert the fluid filler tube into the transmission with a new O-ring.
  22.  
  23. Fill the transmission up with automatic transmission fluid.
  24.  
  25. Install the driveshaft, making sure that the matchmarks line up.
  26.  
  27. Install the front exhaust pipe.
  28.  
  29. Adjust the kickdown and shifter linkages-refer to the procedures in this section.
  30.  
  31. Install the under covers, then lower the vehicle to the ground.
  32.  
  33. Connect the negative battery cable to the battery.
  34.  
  35. Remove the wheel chocks, start the vehicle up and allow it to warm up. While it is warming up, check for any fluid leaks. Once it is warmed up, check the fluid level and add if needed.
  36.  

 
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