Durango, 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
     
    Rear driveshaft
     
    Crankshaft Position (CKP) sensor
     
    Exhaust front pipe
     
    Transmission braces, if equipped
     
    Starter motor
     
    Transmission oil cooler lines
     
    Torque converter access cover
     
    Torque converter
     
    Transmission oil dipstick tube
     
    Vehicle Speed (VSS) sensor connector
     
    Park/Neutral switch connector
     
    Shift cable
     
    Throttle valve cable
     
    Transmission mount and crossmember. Support the transmission.
     
    Front driveshaft and transfer case, if equipped
     
    Transmission flange bolts
     
    Transmission
     

  4.  

To install:

  1. Install or connect the following:

    Transmission. Tighten the flange bolts to 65 ft. lbs. (87 Nm).
     
    Front driveshaft and transfer case, if equipped
     
    Transmission mount and crossmember
     
    Throttle valve cable
     
    Shift cable
     
    Park/Neutral switch connector
     
    VSS sensor connector
     
    Transmission oil dipstick tube
     
    Torque converter. Tighten the bolts to 23 ft. lbs. (31 Nm) for 10.75 inch converters and to 35 ft. lbs. (47 Nm) for 12.2 inch converters.
     
    Torque converter access cover
     
    Transmission oil cooler lines
     
    Starter motor
     
    Transmission braces, if equipped. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    Exhaust front pipe
     
    CKP sensor
     
    Rear driveshaft
     
    Negative battery cable
     

  2.  

42rle



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle
  6.  
  7. Remove any necessary skid plates.
  8.  
  9. Mark propeller shaft and axle companion flanges for assembly alignment.
  10.  
  11. Remove the rear propeller shaft.
  12.  
  13. Remove the front propeller shaft, if necessary.
  14.  
  15. Disconnect wires from the input and output speed sensors.
  16.  
  17. Disconnect wires from the transmission range sensor.
  18.  
  19. Disconnect wires from the solenoid/pressure switch assembly.
  20.  
  21. Remove the bolts holding the exhaust crossover pipe to the pre-catalytic converter pipe flanges.
  22.  
  23. Remove the bolts holding the exhaust crossover pipe to the catalytic converter flange.
  24.  
  25. Disconnect gearshift cable from transmission manual valve lever.
  26.  
  27. Disengage the shift cable from the cable support bracket.
  28.  
  29. Remove the starter motor.
  30.  
  31. Remove the engine to transmission collar.
  32.  
  33. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  34.  
  35. Disconnect the transmission vent hose from the transmission.
  36.  
  37. Remove transfer case.
  38.  
  39. Support rear of engine with safety stand or jack.
  40.  
  41. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  42.  
  43. Remove bolts securing rear support and cushion to transmission and crossmember.
  44.  
  45. Remove bolts attaching crossmember to frame and remove crossmember.
  46.  
  47. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  48.  
  49. Remove all remaining converter housing bolts.
  50.  
  51. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  52.  
  53. Hold torque converter in place during transmission removal.
  54.  
  55. Lower transmission and remove assembly from under the vehicle.
  56.  
  57. To remove torque converter, carefully slide torque converter out of the transmission.
  58.  

To install:


NOTE
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.

  1. 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.
  2.  
  3. Lubricate oil pump seal lip with transmission fluid.
  4.  
  5. Align converter and oil pump.
  6.  
  7. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
  8.  
  9. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13mm to rear of straightedge when converter is fully seated.
  10.  
  11. Temporarily secure converter with C-clamp.
  12.  
  13. Position transmission on jack and secure it with chains.
  14.  
  15. Check condition of converter driveplate. 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.
  16.  
  17. Apply a light coating of high temperature grease to the torque converter hub pocket in the rear pocket of the engine-s crankshaft.
  18.  
  19. Raise transmission and align the torque converter with the drive plate and transmission converter housing with the engine block.
  20.  
  21. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.
  22.  
  23. 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.
  24.  
  25. Install two bolts to attach the transmission to the engine.
  26.  
  27. Install remaining torque converter housing to engine bolts. Tighten to 50 ft. lbs. (68 Nm).
  28.  
  29. Install transfer case, if equipped. Tighten transfer case nuts to 35 Nm (26 ft. lbs.).
  30.  
  31. Install rear transmission crossmember. Tighten crossmember to frame bolts to 50 ft. lbs. (68 Nm).
  32.  
  33. Install rear support to transmission. Tighten bolts to 47 Nm (35 ft. lbs.).
  34.  
  35. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 Nm (35 ft. lbs.). Tighten the clevis bracket to rear support bolt to 50 ft. lbs. (68 Nm).
  36.  
  37. Connect gearshift cable to support bracket and transmission manual lever.
  38.  
  39. Connect input and output speed sensor wires and the transmission range sensor.
  40.  
  41. Connect wires to the solenoid/pressure switch assembly.
    CAUTION
    It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

  42.  
  43. Install torque converter-to-driveplate bolts. Tighten bolts to 88 Nm (65 ft. lbs.).
  44.  
  45. Install starter motor and cooler line bracket.
  46.  
  47. Connect cooler lines to transmission.
  48.  
  49. Install transmission fill tube.
  50.  
  51. Install exhaust components.
  52.  
  53. Align and connect propeller shaft(s).
  54.  
  55. Adjust gearshift cable if necessary.
  56.  
  57. Install any skid plates removed previously.
  58.  
  59. Lower vehicle.
  60.  
  61. Fill transmission with Mopar® ATF +4, Automatic Transmission Fluid or equivalent.
  62.  

545RFE



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle
  6.  
  7. Remove any necessary skid plates.
  8.  
  9. Mark propeller shaft and axle companion flanges for assembly alignment.
  10.  
  11. Remove the rear propeller shaft.
  12.  
  13. Remove the front propeller shaft, if necessary.
  14.  
  15. Remove the engine to transmission collar.
  16.  
  17. Remove the exhaust support bracket from the rear of the transmission.
  18.  
  19. Disconnect and lower or remove any necessary exhaust components.
  20.  
  21. Remove the starter motor.
  22.  
  23. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  24.  
  25. Disengage the output speed sensor connector from the output speed sensor.
  26.  
  27. Disengage the input speed sensor connector from the input speed sensor.
  28.  
  29. Disengage the transmission solenoid/TRS assembly connector from the transmission solenoid/TRS assembly.
  30.  
  31. Disengage the line pressure sensor connector from the line pressure sensor.
  32.  
  33. Disconnect gearshift cable from transmission manual valve lever.
  34.  
  35. Remove the gearshift cable from the shift cable support bracket.
  36.  
  37. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  38.  
  39. Support rear of engine with safety stand or jack.
  40.  
  41. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  42.  
  43. Remove bolts securing rear support and cushion to transmission and crossmember.
  44.  
  45. Remove bolts attaching crossmember to frame and remove crossmember.
  46.  
  47. Remove transfer case.
  48.  
  49. Remove all remaining converter housing bolts.
  50.  
  51. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  52.  
  53. Hold torque converter in place during transmission removal.
  54.  
  55. Lower transmission and remove assembly from under the vehicle.
  56.  
  57. To remove torque converter, carefully slide torque converter out of the transmission.
  58.  

To install:


NOTE
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.

  1. 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.
  2.  
  3. Lubricate oil pump seal lip with transmission fluid.
  4.  
  5. Align converter and oil pump.
  6.  
  7. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
  8.  
  9. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13mm to rear of straightedge when converter is fully seated.
  10.  
  11. Temporarily secure converter with C-clamp.
  12.  
  13. Position transmission on jack and secure it with chains.
  14.  
  15. Check condition of converter driveplate. 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.
  16.  
  17. Apply a light coating of high temperature grease to the torque converter hub pocket in the rear pocket of the engine-s crankshaft.
  18.  
  19. Raise transmission and align the torque converter with the drive plate and transmission converter housing with the engine block.
  20.  
  21. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.
  22.  
  23. 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.
  24.  
  25. Install two bolts to attach the transmission to the engine.
  26.  
  27. Install remaining torque converter housing to engine bolts. Tighten to 50 ft. lbs. (68 Nm).
  28.  
  29. Install transfer case, if equipped. Tighten transfer case nuts to 35 Nm (26 ft. lbs.).
  30.  
  31. Install rear transmission crossmember. Tighten crossmember to frame bolts to 50 ft. lbs. (68 Nm).
  32.  
  33. Install rear support to transmission. Tighten bolts to 47 Nm (35 ft. lbs.).
  34.  
  35. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 Nm (35 ft. lbs.). Tighten the clevis bracket to rear support bolt to 50 ft. lbs. (68 Nm).
  36.  
  37. Remove engine support fixture.
  38.  
  39. Connect gearshift cable to transmission.
  40.  
  41. Connect the wiring harness connector to the solenoid and pressure switch assembly connector. Be sure transmission harnesses are properly routed.
  42.  
  43. Connect the wiring harness connector to the input speed sensor.
  44.  
  45. Connect the wiring harness connector to the output speed sensor.
  46.  
  47. Connect the wiring harness connector to the line pressure sensor.
    CAUTION
    It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

  48.  
  49. Install torque converter-to-driveplate bolts. Tighten bolts to 31 Nm (270 inch lbs.).
  50.  
  51. Install starter motor and cooler line bracket.
  52.  
  53. Connect cooler lines to transmission.
  54.  
  55. Install transmission fill tube.
  56.  
  57. Install exhaust components.
  58.  
  59. Install the structural dust cover onto the transmission and the engine.
  60.  
  61. Align and install the front propeller shaft, if necessary.
  62.  
  63. Align and install the rear propeller shaft.
  64.  
  65. Adjust gearshift cable if necessary.
  66.  
  67. Install any skid plates removed previously.
  68.  
  69. Lower vehicle.
  70.  
  71. Fill transmission with Mopar® ATF +4, Automatic Transmission Fluid.
  72.  

 
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