Commander 2006-2007

Transmission Removal & Installation

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545RFE



4.7L & 5.7L Models
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front and rear driveshafts.
  6.  
  7. Remove the engine to transmission structural cover.

    Click image to see an enlarged view

    Fig. Engine-to-transmission structural cover-5.7L model shown

  8.  
  9. Remove the exhaust support bracket from the rear of the transmission.
  10.  
  11. Disconnect and lower or remove any necessary exhaust components.
  12.  
  13. Rotate the crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  14.  
  15. Disconnect wires from solenoid and pressure switch assembly, input and output speed sensors, and line pressure sensor.
  16.  
  17. Disconnect the gearshift cable from transmission manual valve lever.
  18.  
  19. Remove the clip securing the transfer case shift cable into the cable support bracket.
  20.  
  21. Remove the transfer case assembly from the transmission.
  22.  
  23. Remove the engine oil pan-to-transmission mounting bolts, 5.7L engine only.

    Click image to see an enlarged view

    Fig. Remove the engine oil pan-to-transmission mounting bolts-5.7L engine only.

  24.  
  25. Remove the bolt holding the transmission fill tube to the transmission and remove the fill tube and dipstick.

    Click image to see an enlarged view

    Fig. Remove the bolt (4) holding the fill tube (2) to the transmission (1). Remove the fill tube and dipstick (3) assembly-545RFE transmission shown

  26.  
  27. Disconnect the transmission fluid cooler lines at the transmission fittings and clips.
  28.  
  29. Disconnect the transmission vent hose from the transmission.
  30.  
  31. Support rear of engine with safety stand or jack.
  32.  
  33. Raise the transmission slightly with service jack to relieve load on crossmember and supports.
  34.  
  35. Remove bolts securing rear support and cushion to transmission and crossmember.
  36.  
  37. Remove bolts attaching crossmember to frame and remove crossmember.
  38.  
  39. Remove all remaining transmission-to-engine bolts.

    Click image to see an enlarged view

    Fig. Remove any remaining bolts (3,4) holding the transmission (2) to the engine (1).

  40.  
  41. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  42.  
  43. Hold torque converter in place during transmission removal.
  44.  
  45. Lower transmission and remove assembly from under the vehicle.
  46.  
  47. In order to remove torque converter, carefully slide the torque converter out of the transmission.
  48.  

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. Verify that the converter hub O-ring is properly installed and is free of any debris. 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. Align converter and oil pump.
  8.  
  9. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
  10.  
  11. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13mm ( 1 / 2 in.) to rear of straightedge when converter is fully seated.
  12.  
  13. Temporarily secure converter with C-clamp.
  14.  
  15. Position transmission on jack and secure it with chains.
  16.  
  17. Check condition of converter drive plate. Replace the plate if cracked, distorted or damaged.
    NOTE
    Be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.

  18.  
  19. Apply a light coating of Mopar® High Temp Grease to the torque converter hub pocket in the rear pocket of the engine-s crankshaft.
  20.  
  21. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
  22.  
  23. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
  24.  
  25. 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.
  26.  
  27. Install two bolts to attach the transmission to the engine.
  28.  
  29. Install remaining torque converter housing to engine bolts. Tighten to 50 ft. lbs. (68 Nm).
  30.  
  31. Install the left and right side oil pan-to-transmission bolts and tighten to 40 ft. lbs. (54 Nm), 5.7L engines only.
  32.  
  33. Connect the cooler lines to transmission.
  34.  
  35. Install the transmission fill tube.
  36.  
  37. Install rear transmission crossmember. Tighten crossmember to frame bolts to 50 ft. lbs. (68 Nm).
  38.  
  39. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  40.  
  41. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 35 ft. lbs. (47 Nm). Tighten the clevis bracket to rear support bolt to 50 ft. lbs. (68 Nm).
  42.  
  43. Remove engine support fixture.
  44.  
  45. Install new plastic retainer grommet on any shift cable that was disconnected. Grommets should not be reused. Use pry tool to remove rod from grommet and cut away old grommet. Use pliers to snap new grommet into cable and to snap grommet onto lever.
  46.  
  47. Connect the gearshift cable to transmission.
  48.  
  49. Connect wires to solenoid and pressure switch assembly connector, input and output speed sensors, and line pressure sensor. Be sure transmission harnesses are properly routed.
    NOTE
    It is essential that correct length bolts be used to attach the converter to the drive plate. Bolts that are too long will damage the clutch surface inside the converter.

  50.  
  51. Verify the torque converter is pulled flush up to the drive plate. Tighten bolts to 270 inch lbs. (31 Nm).
  52.  
  53. Install the structural dust cover onto the transmission and the engine.
  54.  
  55. Install the transfer case.
  56.  
  57. Install the starter.
  58.  
  59. Install any exhaust components that were removed for access.
  60.  
  61. Install the front and rear driveshafts.
  62.  
  63. Adjust the gearshift cable if necessary.
  64.  
  65. Lower the vehicle.
  66.  
  67. Fill the transmission with the appropriate fluid to the correct level.
  68.  

NAG1 Transmission



3.7L Models
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front and rear driveshafts.
  6.  
  7. Remove the starter.
    NOTE
    It is not necessary to disconnect the starter motor wires.

  8.  
  9. Remove the structural cover by removing the mounting bolts.

    Click image to see an enlarged view

    Fig. Structural cover and mounting bolts (1,2,3)-3.7L Commander w/NAG1

  10.  
  11. Rotate the crankshaft in clockwise direction until the torque converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  12.  
  13. Disconnect the gearshift cable from the transmission manual valve lever.
  14.  
  15. Remove the shift cable from the gearshift cable bracket.
  16.  
  17. Disconnect the 13-pin plug connector. Turn bayonet lock of guide bushing counterclockwise.
  18.  
  19. Remove the 13-pin connector from the transmission.
  20.  
  21. Disconnect the transmission fluid cooler lines at the transmission.
  22.  
  23. Disconnect the transmission vent hose from the transmission.
  24.  
  25. Remove the bolts holding the transmission fill tube to the transmission.
  26.  
  27. Support rear of engine with safety stand or jack.
  28.  
  29. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  30.  
  31. Remove bolts securing rear support and cushion to transmission crossmember.
  32.  
  33. Remove bolts attaching crossmember to frame and remove crossmember.
  34.  
  35. Remove all remaining bolts holding the engine to the transmission. Note the location of any wiring harness clips.
  36.  
  37. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  38.  
  39. Hold torque converter in place during transmission removal.
  40.  
  41. Lower transmission and remove assembly from under the vehicle.
  42.  
  43. To remove torque converter, carefully slide torque converter out of the transmission.
  44.  

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 on 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 straightedge. Surface of converter lugs should be at least 19mm ( 3 / 4 in.) to rear of straightedge 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 drive plate. 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. (36 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 35 ft. lbs. (47 Nm). Tighten the clevis bracket to rear support bolt to 50 ft. lbs. (68 Nm).
  38.  
  39. Remove engine support fixture.
  40.  
  41. Install the engine to transmission structural cover.
  42.  
  43. Connect the gearshift cable to the gearshift cable bracket and transmission.
  44.  
  45. Check O-ring on plug connector, and replace if necessary.
  46.  
  47. Install the plug connector into the guide bushing. Turn bayonet lock of guide bushing clockwise to connect plug connector.
    WARNING
    It is essential that correct length bolts be used to attach the converter to the drive plate. Bolts that are too long will damage the clutch surface inside the converter.

  48.  
  49. Install all torque converter-to-drive plate bolts by hand.
  50.  
  51. Verify the torque converter is pulled flush up to the drive plate. Tighten bolts to 30 ft. lbs. (42 Nm).
  52.  
  53. Install the starter motor.
  54.  
  55. Install the transmission fill tube.
  56.  
  57. Connect the cooler lines to transmission.
  58.  
  59. Align and connect drive shafts.
  60.  
  61. Adjust gearshift cable if necessary.
  62.  
  63. Lower the vehicle.
  64.  
  65. Connect negative battery cable.
  66.  
  67. Fill the transmission with the appropriate fluid to the correct level.
  68.  
  69. Start the engine, check for leaks and verify proper transmission operation.
  70.  

 
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