Ram Truck 1500, 2500 & 3500 (2006-2008)

Transmission Removal & Installation

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42rle



  1. Before servicing the vehicle, refer to the Precautions Section.
  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 the input and output speed sensors.
  16.  
  17. Disconnect the transfer case shift motor and mode sensor assembly.
  18.  
  19. Disconnect the variable line pressure connector from the transmission, if equipped.
  20.  
  21. Disconnect the transmission range sensor.
  22.  
  23. Disconnect wires from the solenoid/pressure switch assembly.
  24.  
  25. Remove the bolts holding the exhaust crossover pipe to the pre-catalytic converter pipe flanges.
  26.  
  27. Remove the bolts holding the exhaust crossover pipe to the catalytic converter flange.
  28.  
  29. Disconnect gearshift cable from transmission manual valve lever.
  30.  
  31. Disengage the shift cable from the cable support bracket.
  32.  
  33. Remove the starter motor.
  34.  
  35. Remove the engine to transmission collar.
  36.  
  37. 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.
  38.  
  39. Disconnect the transmission vent hose from the transmission.
  40.  
  41. Remove transfer case.
  42.  
  43. Support rear of engine with safety stand or jack.
  44.  
  45. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  46.  
  47. Remove bolts securing rear support and cushion to transmission and crossmember.(
  48.  
  49. Remove bolts attaching crossmember to frame and remove crossmember.
  50.  
  51. Disconnect transmission fluid cooler line sat transmission fittings and clips.
  52.  
  53. Remove all remaining converter housing bolts.
  54.  
  55. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  56.  
  57. Hold torque converter in place during transmission removal.
  58.  
  59. Lower transmission and remove assembly from under the vehicle.
  60.  
  61. To remove torque converter, carefully slide torque converter out of the transmission.
  62.  

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 1 / 2 inch (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 Mopar® High Temp 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.
  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 35 ft. lbs. (47 Nm).
  34.  
  35. 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).
  36.  
  37. Connect gearshift cable to support bracket and transmission manual lever.
  38.  
  39. Connect the input and output speed sensor and the transmission range sensor.
  40.  
  41. Connect the variable line pressure connector, if equipped.
  42.  
  43. Connect wires to the solenoid/pressure switch assembly.
    WARNING
    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.

  44.  
  45. Install torque converter-to-driveplate bolts. Tighten bolts to 65 inch lbs. (88 Nm).
  46.  
  47. Install starter motor and cooler line bracket.
  48.  
  49. Connect cooler lines to transmission.
  50.  
  51. Install transmission fill tube.
  52.  
  53. Install exhaust components.
  54.  
  55. Align and connect propeller shaft(s).
  56.  
  57. Adjust gearshift cable if necessary.
  58.  
  59. Install any skid plates removed previously.
  60.  
  61. Lower the vehicle.
  62.  
  63. Connect the negative battery cable.
  64.  
  65. Fill transmission with Mopar® ATF +4, Automatic Transmission Fluid.
  66.  

45RFE/545RFE



  1. Before servicing the vehicle, refer to the Precautions Section.
  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 structural dust cover.
  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. Disconnect the transmission vent hose from the transmission.
  36.  
  37. Support rear of engine with safety stand or jack.
  38.  
  39. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  40.  
  41. Remove bolts securing rear support and cushion to transmission and crossmember.
  42.  
  43. Remove transfer case, if necessary.
  44.  
  45. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  46.  
  47. Remove all remaining converter housing bolts.
  48.  
  49. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  50.  
  51. Hold torque converter in place during transmission removal.
  52.  
  53. Lower transmission and remove assembly from under the vehicle.
  54.  
  55. To remove torque converter, carefully slide torque converter out of the transmission.
  56.  

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 1 / 2 inch (13mm) 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 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.
  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 transmission converter housing with the engine block.
  22.  
  23. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with 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. 50 ft. lbs (68 Nm).
  30.  
  31. Install transfer case, if equipped. Tighten transfer case nuts to 26 ft. lbs. (35 Nm).
  32.  
  33. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  34.  
  35. 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 ).
  36.  
  37. Remove engine support fixture.
  38.  
  39. Connect gearshift cable to transmission.
  40.  
  41. Connect wires to solenoid and pressure switch assembly connector.
  42.  
  43. Connect wires to input and output speed sensors.
  44.  
  45. Connect wires to line pressure sensor.
    NOTE
    Be sure transmission harnesses are properly routed.


    WARNING
    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.

  46.  
  47. Install torque converter-to-driveplate bolts. Tighten bolts to 270 inch lbs. (31 Nm).
  48.  
  49. Install starter motor and cooler line bracket.
  50.  
  51. Connect cooler lines to transmission.
  52.  
  53. Install transmission fill tube.
  54.  
  55. Install exhaust components, if necessary.
  56.  
  57. Install the structural dust cover onto the transmission and the engine.
  58.  
  59. Align and connect propeller shaft(s).
  60.  
  61. Adjust gearshift cable if necessary.
  62.  
  63. Install any skid plates removed previously.
  64.  
  65. Lower vehicle.
  66.  
  67. Fill transmission with Mopar® ATF +4, Automatic Transmission Fluid.
  68.  

48RE




NOTE
The overdrive unit can be removed and serviced separately. It is not necessary to remove the entire transmission assembly to perform overdrive unit repairs.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove the transfer case skid plate if equipped.
  8.  
  9. Disconnect and lower or remove any necessary exhaust components.
  10.  
  11. Remove engine-to-transmission struts.
  12.  
  13. Remove starter motor.
  14.  
  15. Disconnect and remove the crankshaft position sensor.
  16.  
  17. If transmission is being removed for overhaul, remove transmission oil pan, drain fluid and reinstall pan.
  18.  
  19. Remove torque converter access cover.
  20.  
  21. 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.
  22.  
  23. Mark propeller shaft and axle yokes for assembly alignment. Then disconnect and remove propeller shaft. On 4WD models, remove both propeller shafts.
  24.  
  25. Disconnect wires from the transmission range sensor and transmission solenoid connector.
  26.  
  27. Disconnect gearshift cable from the transmission manual lever.
  28.  
  29. For vehicles with gas engines, disconnect throttle valve cable from transmission bracket and throttle valve lever.
  30.  
  31. For vehicles with a diesel engine, remove the bolts holding the Transmission Throttle Valve Actuator (TTVA) to the transmission case.
  32.  
  33. Allow the TTVA to rotate clockwise away from the transmission.
  34.  
  35. Remove the wiring connector from the TTVA.
  36.  
  37. Lift the TTVA straight upward and off the throttle valve shaft.
  38.  
  39. On 4WD models, disconnect shift rod from transfer case shift lever.
  40.  
  41. Support rear of engine with safety stand or jack.
  42.  
  43. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  44.  
  45. Remove the nuts securing the rear support to the transmission crossmember.
  46.  
  47. Remove the bolts holding the rear support to the transmission remove the rear support.
  48.  
  49. Remove bolts attaching crossmember to frame and remove crossmember.
  50.  
  51. On 4WD models, remove transfer case.
  52.  
  53. Remove fill tube bracket bolts and pull tube out of transmission. Retain fill tube seal. On 4X4 models, it will also be necessary to remove bolt attaching transfer case vent tube to converter housing.
  54.  
  55. Disconnect fluid cooler lines at transmission.
  56.  
  57. Remove all bolts holding the transmission to the engine adapter, diesel engines.
  58.  
  59. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  60.  
  61. Lower transmission and remove assembly from under the vehicle.
  62.  
  63. To remove torque converter, remove C-clamp from edge of bell housing and carefully slide torque converter out of the transmission.
  64.  
  65. Remove all bolts holding the transmission to the engine adapter, gas engines.
  66.  
  67. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  68.  
  69. Lower transmission and remove assembly from under the vehicle.
  70.  
  71. To remove torque converter, remove C-clamp from edge of bell housing and carefully slide torque converter out of the transmission.
  72.  

To install:

  1. Check torque converter hub inner and outer diameters and hub drive notches for sharp edges burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation
  2.  
  3. Lubricate pocket in the rear oil pump seal lip with transmission fluid.
  4.  
  5. Lubricate converter pilot hub of the crankshaft with a light coating of Mopar® High Temp Grease.
  6.  
  7. Align and install converter in 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 0.75 inch (19mm) to rear of straightedge when converter is fully seated.
  12.  
  13. Temporarily secure converter with C-clamp.
  14.  
  15. DIESEL ENGINES are as follows:
    1. Position transmission on jack and secure it with chains.
    2.  
    3. 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.
    4.  
    5. Raise transmission and align converter with drive plate and converter housing with engine block.
    6.  
    7. Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.
    8.  
    9. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.
    10.  
    11. Install bolts attaching transmission to engine adapter.
    12.  

  16.  
  17. GAS ENGINES are as follows:
    1. Position transmission on jack and secure it with chains. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
    2.  
    3. Raise transmission and align converter with drive plate and converter housing with engine block.
    4.  
    5. Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.
    6.  
    7. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.
    8.  
    9. Install bolts attaching transmission to engine.
    10.  

  18.  
  19. Install rear support.
  20.  
  21. Install the rear transmission crossmember.
  22.  
  23. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember
  24.  
  25. Remove engine support fixture.
  26.  
  27. Install the transfer case, if equipped.
  28.  
  29. Install crankshaft position sensor.
  30.  
  31. Connect gearshift cable and throttle cable (gas engines only) to transmission.
  32.  
  33. For vehicles equipped with a diesel engine, position the Transmission Throttle Valve Actuator (TTVA) over the throttle valve shaft.
  34.  
  35. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft.
  36.  
  37. Install the wiring connector to the TTVA.
  38.  
  39. Rotate the TTVA to the transmission case and install the bolts to hold the TTVA to the transmission.
  40.  
  41. Tighten the bolts to 75 inch lbs. (8.5 Nm).
  42.  
  43. Initialize the TTVA.
  44.  
  45. Connect cooler lines to transmission.
  46.  
  47. Connect wires to the transmission range sensor and transmission solenoid connector. Be sure the transmission harnesses are properly routed.
  48.  
  49. Install torque converter-to-driveplate bolts.
  50.  
  51. Install converter housing access cover.
  52.  
  53. Install starter motor and cooler line bracket.
  54.  
  55. Install transmission fill tube. Install new seal on tube before installation.
  56.  
  57. Install any exhaust components previously removed.
  58.  
  59. Align and connect propeller shaft.
  60.  
  61. Adjust gearshift cable and throttle valve cable, if necessary.
  62.  
  63. Install the transfer case skid plate, if equipped.
  64.  
  65. Lower the vehicle.
  66.  
  67. Fill transmission with Mopar® ATF +4, Automatic Transmission fluid.
  68.  

68RFE



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove any necessary skid plates.
    NOTE
    Mark propeller shaft and axle companion flanges for assembly alignment.

  8.  
  9. Remove the rear propeller shaft.
  10.  
  11. Remove the front propeller shaft, if necessary.
  12.  
  13. Remove the exhaust support bracket from the front and rear of the transmission (if equipped).
  14.  
  15. Disconnect and lower or remove any necessary exhaust components.
  16.  
  17. Remove the bolts securing the power bending bracket to the engine block and the transmission case.
  18.  
  19. Remove the power bending bracket.
  20.  
  21. Loosen the inspection cover bolts and remove the inspection cover.
  22.  
  23. Remove the transmission dust shield.
  24.  

To install:

  1. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 800/1000 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 in front of the bell housing face about 1 inch, (25 mm).
  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 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
  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 transmission converter housing with the engine block.
  22.  
  23. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels while positioning filler tube into the filler tube bore.
  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 transfer case, if equipped. Tighten transfer case nuts to 26 ft. lbs. (35 Nm).
  32.  
  33. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  34.  
  35. 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).
  36.  
  37. Remove engine support fixture.
  38.  
  39. Install the transmission inspection cover. Tighten the bolts to 88 inch lbs. (10Nm).
  40.  
  41. Install the power bending bracket.
  42.  
  43. Install the transmission dust shield.
  44.  
  45. Connect gearshift cable to transmission.
  46.  
  47. Connect wires to solenoid and pressure switch assembly connector.
  48.  
  49. Connect wires to input and output speed sensor.
  50.  
  51. Connect wires to line pressure sensor. Be sure transmission harnesses are properly routed.
  52.  
  53. Install the differential pressure sensor bolt (if equipped). Tighten bolt to 88 inch lbs. (10Nm).
    WARNING
    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.

  54.  
  55. Install torque converter-to-driveplate bolts. Tighten bolts to 270 in. lbs. (31 Nm).
  56.  
  57. Connect cooler lines to transmission.
  58.  
  59. Install transmission fill tube bolt. Tighten bolt to 88 in. lbs. (10Nm).
  60.  
  61. Install exhaust components, if necessary.
  62.  
  63. Align and connect propeller shaft(s).
  64.  
  65. Adjust gearshift cable if necessary.
  66.  
  67. Install any skid plates removed previously.
  68.  
  69. Lower the vehicle.
  70.  
  71. Fill transmission with Mopar® ATF +4, Automatic Transmission Fluid.
  72.  

AS68RC



  1. Before servicing the vehicle, refer to the Precautions Section.
  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 inspection cover.
  16.  
  17. Remove the exhaust support bracket from the rear of the transmission.
  18.  
  19. Remove the exhaust particulate filter
  20.  
  21. Rotate crankshaft in clockwise direction until torque converter bolts (4) are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
    WARNING
    Tag the orientation of all electrical connectors. Some electrical connectors may be interchangeable, damage to the electrical system may occur if the connectors are reversed.

  22.  
  23. Disconnect the input speed sensor, output speed sensor, electrical connectors and position the harness aside.
  24.  
  25. Disconnect the transmission valve body solenoid and pressure switch electrical connectors and position harness aside.
  26.  
  27. Disconnect the cooler line temperature sensor electrical connector and position harness aside.
  28.  
  29. Disconnect gearshift cable ball socket from transmission manual valve lever.
  30.  
  31. Remove the shift cable from the shift cable bracket.
  32.  
  33. Remove the shift cable bracket bolt and shift cable bracket.
  34.  
  35. Remove the bolt securing the differential pressure sensor to the transmission case, if equipped.
  36.  
  37. Disconnect the transmission vent hose from the transmission.
  38.  
  39. Support rear of engine with safety stand or jack.
    NOTE
    Support the transmission where the transmission oil pan meets the transmission case.

  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 transfer case, if necessary.
  46.  
  47. Remove the nuts securing the power bending bracket to extension housing, if equipped.
  48.  
  49. Disconnect transmission fluid cooler lines at transmission Jiffy Tite fittings with quick connect tool 9546.
  50.  
  51. Remove all remaining converter housing bolts.
  52.  
  53. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  54.  
  55. Hold torque converter in place during transmission removal.
  56.  
  57. Lower transmission and remove assembly from under the vehicle.
    WARNING
    Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission.

  58.  
  59. To remove torque converter, carefully slide torque converter out of the transmission.
  60.  

To install:


NOTE
After the installation of the transmission, a quick learn must be performed using the scan tool.

  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 trans jell or petroleum jelly.
  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 (1) and straightedge (2). Surface of converter lugs should be at least 1.12 inch (28.2 mm) 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 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.
  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 transmission converter housing with the engine block.
  22.  
  23. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with 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 the bolts to attach the transmission to the engine. Tighten the bolts to 47 inch lbs. (64 Nm).
  28.  
  29. It is essential that correct length bolts be used to attach the converter to the driveplate. Failure to follow this caution may result in transmission damage.
  30.  
  31. Rotate crankshaft with socket wrench on dampener bolt in clockwise direction and install NEW torque converter to driveplate bolts. Tighten bolts to 270 in. lbs. (31 Nm).
    WARNING
    If replacing a engine mount / bracket, be certain to inspect all other engine mounts in the system. Failure to follow this caution may result in damage to the vehicle.

  32.  
  33. Install the power bending bracket onto the extension housing, if equipped. Tighten the power bending bracket nuts to 22 ft. lbs. (30 Nm).
  34.  
  35. Install transfer case, if equipped. Tighten transfer case nuts to 26 ft. lbs. (35 Nm).
  36.  
  37. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  38.  
  39. 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).
  40.  
  41. Remove engine support fixture.
    WARNING
    Install the electrical connectors correctly. Some electrical connectors may be interchangeable, damage to the electrical system may occur if the connectors are reversed.

  42.  
  43. Connect wire harnesses to solenoids and transmission range sensor assembly.
  44.  
  45. Install shift cable bracket and the shift cable bracket bolt. Tighten bolt to 20 ft. lbs. (27 Nm).
  46.  
  47. Install the shift cable into the shift cable bracket.
  48.  
  49. Connect gearshift cable ball socket from transmission manual valve lever.
  50.  
  51. Connect the wire harness to the input speed sensor and the output speed sensor.
  52.  
  53. Connect the electrical harness to torque converter temperature sensor and be certain transmission harnesses are properly routed.
  54.  
  55. Connect cooler lines to transmission.
  56.  
  57. Install transmission fill tube.
  58.  
  59. Install bolt securing the differential pressure sensor onto the transmission case. Tighten the bolt to 88 inch lbs. (10Nm).
  60.  
  61. Install exhaust particulate filter.
  62.  
  63. Align and connect propeller shaft(s).
  64.  
  65. Adjust gearshift cable if necessary.
  66.  
  67. Install any skid plates removed previously.
  68.  
  69. Lower the vehicle.
  70.  
  71. Fill transmission with MOPAR® AS68RC Automatic Transmission Fluid.
  72.  

 
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