Dakota, 2001-2005

Transmission Removal & Installation

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  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever and tower assembly
     
    Crankshaft Position (CKP) sensor
     
    Skidplate, if equipped
     
    Rear driveshaft
     
    Front driveshaft, if equipped
     
    Transfer case shift linkage, if equipped
     
    Transmission mount and crossmember. Support the transmission.
     
    Exhaust front pipe
     
    Clutch slave cylinder
     
    Starter motor
     
    Vehicle Speed (VSS) sensor connector
     
    Reverse light switch connector
     
    Transmission flange bolts
     
    Transmission
     

  4.  

To install:

  1. Install or connect the following:

    Transmission. Tighten the flange bolts to 40-45 ft. lbs. (54-61 Nm).
     
    Reverse light switch connector
     
    Vehicle Speed (VSS) sensor connector
     
    Starter motor
     
    Clutch slave cylinder
     
    Exhaust front pipe
     
    Transmission mount and crossmember. Tighten the fasteners to 50 ft. lbs. (68 Nm).
     
    Transfer case shift linkage, if equipped
     
    Front driveshaft, if equipped
     
    Rear driveshaft
     
    Skidplate, if equipped
     
    CKP sensor
     
    Shift lever and tower assembly
     
    Negative battery cable
     

  2.  

2-Wheel Drive



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Shift transmission into Neutral.
  6.  
  7. Remove floor console.
  8.  
  9. Remove shift lever boot.
  10.  
  11. Remove the shift lever extension from the shift tower and lever assembly.
  12.  
  13. Raise vehicle.
  14.  
  15. Remove skid plate, if equipped (4WD).
  16.  
  17. If transmission will be disassembled for repair, remove drain plug and drain lubricant from transmission.
  18.  
  19. Mark propeller shafts and companion flange for assembly reference.
  20.  
  21. Disconnect and remove propeller shafts.
  22.  
  23. Disconnect and remove exhaust system Y-pipe. Then disconnect and lower remaining exhaust pipes for clearance as necessary.
  24.  
  25. Disconnect backup light switch wires.
  26.  
  27. Remove bolts/nuts attaching transmission to rear mount.
  28.  
  29. Support transmission with a transmission jack. Secure transmission to jack with safety chains.
  30.  
  31. Remove rear crossmember.
  32.  
  33. Remove bolts attaching clutch slave cylinder to clutch housing. Then move cylinder aside for working clearance.
  34.  
  35. Remove starter.
  36.  
  37. Remove transmission dust shield.
  38.  
  39. Remove transmission harness wires from clips on transmission shift cover.
  40.  
  41. Lower transmission slightly.
  42.  
  43. Remove the bolts attaching the shift tower and lever assembly to the transmission housing. Then remove the shift tower and lever assembly.
  44.  
  45. Remove bolts attaching transmission to engine.
  46.  
  47. Slide transmission and jack rearward until input shaft clears clutch disc.
  48.  
  49. Lower transmission jack and remove transmission from under vehicle.
  50.  

To install:


NOTE
If a new transmission is being installed, be sure to use all components supplied with the new transmission. For example, if a new shift tower is supplied with the new transmission, do not re-use the original shift tower.

  1. Apply light coat of Mopar® high temperature bearing grease to contact surfaces of following components:

    input shaft splines.
     
    release bearing slide surface of front retainer.
     
    release bearing bore.
     
    release fork.
     
    release fork ball stud.
     
    propeller shaft slip yoke.
     

  2.  
  3. Apply sealer to threads of drain plug, then install plug in case.
  4.  
  5. Mount transmission on jack and position transmission under vehicle. Secure transmission to jack with safety chains.
  6.  
  7. Raise transmission until input shaft is centered in clutch disc hub.
  8.  
  9. Move transmission forward and start input shaft in clutch disc.
  10.  
  11. Work transmission forward until seated against engine. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
  12.  
  13. Install and tighten transmission to engine bolts to 108 Nm (80 ft. lbs.).
  14.  
  15. Position transmission harness wires in clips on shift cover.
  16.  
  17. Install slave cylinder and shield, if equipped.
  18.  
  19. Install transmission mount on transmission or rear crossmember.
  20.  

4-Wheel Drive



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Shift transmission into Neutral.
  6.  
  7. Remove floor console.
  8.  
  9. Remove shift lever boot.
  10.  
  11. Remove the shift lever extension from the shift tower and lever assembly.
  12.  
  13. Raise vehicle.
  14.  
  15. Remove skid plate, if equipped (4WD).
  16.  
  17. If transmission will be disassembled for repair, remove drain plug and drain lubricant from transmission.
  18.  
  19. Mark propeller shafts and companion flange for assembly reference.
  20.  
  21. Disconnect and remove propeller shafts.
  22.  
  23. Disconnect and remove exhaust system Y-pipe. Then disconnect and lower remaining exhaust pipes for clearance as necessary.
  24.  
  25. Disconnect backup light switch wires.
  26.  
  27. Support engine with adjustable safety stand.
  28.  
  29. Disconnect transfer case shift linkage at transfer case range lever.
  30.  
  31. Remove transfer case shift lever from transmission.
  32.  
  33. Remove bolts/nuts attaching transmission to rear support.
  34.  
  35. Remove crossmember bolts/nuts and remove crossmember.
  36.  
  37. Support transfer case with transmission jack. Secure transfer case to jack with safety chains.
  38.  
  39. Remove transfer case attaching nuts.
  40.  
  41. Move transfer case rearward until input gear clears transmission output shaft.
  42.  
  43. Lower transfer case assembly and move it from under vehicle.
  44.  
  45. Support transmission with transmission jack. Secure transmission to jack with safety chains.
  46.  
  47. Remove transmission harness from retaining clips on transmission shift cover.
  48.  
  49. Remove clutch slave cylinder splash shield, if equipped.
  50.  
  51. Remove clutch slave cylinder attaching nuts. Move cylinder aside for working clearance.
  52.  
  53. Remove starter.
  54.  
  55. Remove transmission splash shield.
  56.  
  57. Lower transmission slightly
  58.  
  59. Remove bolts attaching shift tower and lever assembly to rear case. Then remove shift tower and lever as an assembly.
  60.  
  61. Remove bolts attaching transmission to engine.
  62.  
  63. Move transmission rearward until input shaft clears clutch disc.
  64.  
  65. Lower transmission and remove it from under vehicle.
  66.  

To install:


NOTE
If a new transmission is being installed, be sure to use all components supplied with the new transmission. For example, if a new shift tower is supplied with the new transmission, do not re-use the original shift tower.

  1. Apply light coat of Mopar® high temperature bearing grease to contact surfaces of following components:

    input shaft splines.
     
    release bearing slide surface of front retainer.
     
    release bearing bore.
     
    release fork.
     
    release fork ball stud.
     
    propeller shaft slip yoke.
     

  2.  
  3. Apply sealer to threads of drain plug, then install plug in case.
  4.  
  5. Mount transmission on jack and position transmission under vehicle. Secure transmission to jack with safety chains.
  6.  
  7. Raise transmission until input shaft is centered in clutch disc hub.
  8.  
  9. Move transmission forward and start input shaft in clutch disc.
  10.  
  11. Work transmission forward until seated against engine. Do not allow transmission to remain unsupported after input shaft has entered clutch disc.
  12.  
  13. Install and tighten transmission to engine bolts to 108 Nm (80 ft. lbs.).
  14.  
  15. Position transmission harness wires in clips on shift cover.
  16.  
  17. Install slave cylinder and shield, if equipped.
  18.  
  19. Install transmission mount on transmission or rear crossmember.
  20.  
  21. Install transfer case shift lever on transmission.
  22.  
  23. Install rear crossmember.
    NOTE
    Ensure wiring harness is clear before installing crossmember.

  24.  
  25. Remove transmission jack and engine support fixture.
  26.  
  27. Install transfer case on transmission jack. Secure transfer case to jack with safety chains.
  28.  
  29. Raise jack and align transfer case input gear with transmission output shaft.
  30.  
  31. Move transfer case forward and seat it on transmission.
  32.  
  33. Install and tighten transfer case attaching nuts. Tighten nuts to 41-47 Nm (30-35 ft. lbs.) if case has 3 / 8 studs, or 30-41 Nm (22-30 ft. lbs.) if case has 5 / 16 studs.
  34.  
  35. Connect backup light switch wires.
  36.  
  37. Install transmission dust cover.
  38.  
  39. Install starter.
  40.  
  41. Install transfer case shift lever to side of transfer case.
  42.  
  43. Connect transfer case shift lever to range lever on transfer case.
  44.  
  45. Align and connect propeller shafts.
  46.  
  47. Fill transmission with required lubricant. Check lubricant level in transfer case and add lubricant if necessary.
  48.  
  49. Install transfer case skid plate, if equipped, and crossmember. Tighten attaching bolts/nuts to 41 Nm (30 ft. lbs.).
  50.  
  51. Install exhaust system components.
  52.  
  53. Lower vehicle.
  54.  
  55. Install shift tower and lever assembly. Tighten shift tower bolts to 7-10 Nm (5-7 ft. lbs.).
  56.  
  57. Install shift lever boot.
  58.  
  59. Install floor console.
  60.  
  61. Connect battery negative cable.
  62.  

 
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