Transmission Replacement All Wheel Drive

Note: NEW cooler pipe O-rings and torque converter bolts will be required each time the transmission is removed and installed.

1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.
2. Remove the exhaust system. Refer to Exhaust System Replacement.
3. Remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
4. Remove the front and rear propeller shafts. Refer to Front Propeller Shaft Replacement and Rear Propeller Shaft Replacement.



5. Disconnect the shift linkage from the transmission.



6. Disconnect the transmission wiring harness connector (5) from the transmission by releasing the locking mechanism and rotating the latch counterclockwise.
7. Disconnect the wiring harness retainers (4) from the transmission.
8. Remove the transmission vent hose from the retaining clips (6) on the transmission mount assembly.
9. Remove the oxygen sensor wiring harness retainer from the transmission.
10. Place an oil drain pan under the transmission fluid cooler pipes.



11. Remove the transmission fluid cooler pipes (1) from the transmission, and position aside. Refer to Transmission Fluid Cooler Hose/Pipe Replacement.
12. Remove and discard the O-rings. Do NOT reuse the O-rings.
13. Plug the open outlet ports to prevent fluid loss and contamination.



14. Remove the transmission close out plug (1).
15. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment.
16. Remove the starter motor. Refer to Starter Motor Replacement.



17. Repeat the following steps for all torque converter bolts (1):

17.1.

Rotate the harmonic balancer center bolt clockwise ONLY, in order to align the torque converter bolt with the access hole.

17.2.

Remove and discard the torque converter bolt.




18. Disconnect the intermediate shaft from the power steering gear. Refer to Steering Gear Replacement.



19. Support the transmission with a suitable transmission jack.
20. Remove the transmission mount assembly. Refer to Transmission Mount Replacement.
21. Support the rear of the front frame with adjustable jack stands.
22. Remove the bolts at the rear of the front frame.
23. Loosen the bolts at the front of the front frame two turns but do NOT remove the bolts.
24. Lower the rear of the front frame and the transmission.



25. Lower the transmission and remove the vent hose (2) from the vent tube.
26. Position the wire harness and vent tube aside.
27. Remove the transfer case. Refer to Transfer Case Assembly Replacement.



28. Remove the transmission mounting bolts (1-6).
29. Pull the transmission free from the engine dowels.

Note: Ensure clearance is maintained between the transmission and the following:

•	The wiring harness

•	The vent tube

•	The cooler pipes

30. Carefully lower the transmission from the vehicle.
31. Flush the transmission oil cooler if necessary. Refer to Transmission Fluid Cooler Flushing and Flow Test.

Note: Ensure clearance is maintained between the transmission and the following:

•	The wiring harness

•	The vent tube

•	The cooler pipes

1. Using the transmission jack, carefully raise the transmission to the engine.



2. Align the transmission with the engine dowels.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the transmission mounting bolts and tighten to 50 N·m (37 lb ft).
4. Install the transfer case. Refer to Transfer Case Assembly Replacement.



5. Remove the support stand from under the engine oil pan.
6. Using the transmission jack. Lower the engine and transmission assembly only enough to gain access to the vent hose tube.
7. Install the vent hose (2) to the vent tube.
8. Position the engine wiring harness to the original location.
9. Raise the transmission to the installed position.
10. Install the bolts at the rear of the front frame and properly torque all frame bolts. Refer to Front Frame Replacement for proper frame bolt tightening information.



11. Install the transmission mount assembly. Refer to Transmission Mount Replacement.
12. Remove the transmission jack.



13. Connect the intermediate shaft to the power steering gear. Refer to Steering Gear Replacement.
14. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure.




Note: Torque converter bolts are self locking and must be replaced with NEW torque converter bolts every time the bolts are removed.

15. Complete the following steps for all torque converter bolts (1):

15.1.

Rotate the harmonic balancer center bolt clockwise ONLY, in order to align the torque converter bolt holes in the flexplate/flywheel with the access hole in the engine block.

15.2.

To aid in alignment of the torque converter to the flexplate/flywheel. Install all NEW torque converter bolts (1) before fully tightening to 63 N·m (46 lb ft).




16. Install the transmission close out plug (1).
17. Install the starter motor. Refer to Starter Motor Replacement.



18. Place NEW O-rings over the transmission fluid cooler pipes.
19. Install the transmission fluid cooler pipes (1) to the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Replacement.



20. Install the transmission vent hose to the retaining clips (6) on the transmission mount assembly.
21. Install the wiring harness retainers (4) to the transmission.
22. Connect the transmission wiring harness connector (5) to the transmission by rotating the locking latch clockwise.
23. Install the oxygen sensor wiring harness retainer to the transmission.



24. Install the shift linkage to the transmission.
25. Install the transmission manual shift shaft nut and tighten to 15 N·m (11 lb ft).
26. Install the front and rear propeller shafts. Refer to Front Propeller Shaft Replacement and Rear Propeller Shaft Replacement.
27. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
28. Install the exhaust system. Refer to Exhaust System Replacement.
29. Lower the vehicle.
30. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.
31. Check the transmission fluid level and fill if necessary. Refer to Transmission Fluid Check.
32. Adjust the shift control linkage. Refer to Shift Control Linkage Adjustment.

Complete the following procedure after the transmission is installed in the vehicle:

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. While the engine continues to idle, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Inspect for fluid leaks while the engine is idling.
5. Perform a final inspection for the proper fluid level.
6. Lower the vehicle.
7. Calibrate the transmission control module (TCM). Refer to Control Module References.

Note: It is recommended that transmission adaptive pressure (TAP) information be reset.

Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions.
9. Road test the vehicle.

Transmission Replacement Rear Wheel Drive

Note: NEW cooler pipe O-rings and torque converter bolts will be required each time the transmission is removed and installed.

1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.
2. Remove the exhaust system. Refer to Exhaust System Replacement.
3. Remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
4. Remove the propeller shaft. Refer to Rear Propeller Shaft Replacement.



5. Disconnect the shift linkage from the transmission.



6. Remove the transmission vent hose from the retaining clips (6) on the transmission support.



7. Disconnect the transmission wiring harness connector (4) from the transmission by releasing the locking mechanism and rotating the latch counterclockwise.
8. Remove the wiring harness retainers (1) from the transmission.
9. Remove the oxygen sensor wiring harness connector (2) from the transmission.
10. Place an oil drain pan under the transmission fluid cooler pipes.



11. Remove the transmission fluid cooler pipes (1) from the transmission, and position aside. Refer to Transmission Fluid Cooler Hose/Pipe Replacement.
12. Remove and discard the O-rings. Do NOT reuse the O-rings.
13. Plug the open outlet ports to prevent fluid loss and contamination.



14. Remove the transmission close out plug (1).
15. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment.
16. Remove the starter motor. Refer to Starter Motor Replacement.



17. Repeat the following steps for all torque converter bolts (1):

17.1.

Rotate the harmonic balancer center bolt clockwise ONLY, in order to align the torque converter bolt with the access hole.

17.2.

Remove and discard the torque converter bolt.

18. Support the transmission with a suitable transmission jack.
19. Remove the transmission support. Refer to Transmission Support Replacement.
20. Lower the transmission.



21. Disconnect the transmission vent hose (4) from the transmission vent pipe (1).



22. Remove the wiring harness retainers (2) from the transmission.
23. Position the transmission wiring harness (1) and vent tube out of the way.



24. Remove the transmission mounting bolts (1-6).
25. Pull the transmission free from the engine dowels.

Note: Ensure clearance is maintained between the transmission and the following:

•	The wiring harness

•	The vent tube

•	The cooler pipes

26. Carefully lower the transmission from the vehicle.
27. Flush the transmission oil cooler if necessary. Refer to Transmission Fluid Cooler Flushing and Flow Test.

Note: Ensure clearance is maintained between the transmission and the following:

•	The wiring harness

•	The vent tube

•	The cooler pipes

1. Using the transmission jack, carefully raise the transmission to the engine.



2. Align the transmission with the engine dowels.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the transmission mounting bolts and tighten to 50 N·m (37 lb ft).



4. Position the engine wiring harness (1) to the original location.
5. Install the wiring harness retainers (2) to the transmission.



6. Connect the transmission vent hose (4) to the transmission vent pipe (1).
7. Raise the transmission to the installed position.
8. Install the transmission support. Refer to Transmission Support Replacement.
9. Remove the jack from under the transmission.
10. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure.




Note: Torque converter bolts are self locking and must be replaced with NEW torque converter bolts every time the bolts are removed.

11. Complete the following steps for all torque converter bolts (1):

11.1.

Rotate the harmonic balancer center bolt clockwise ONLY, in order to align the torque converter bolt holes in the flexplate/flywheel with the access hole in the engine block.

11.2.

To aid in alignment of the torque converter to the flexplate/flywheel. Install all NEW torque converter bolts before fully tightening to 63 N·m (46 lb ft).

12. Remove the starter motor. Refer to Starter Motor Replacement.



13. Install the transmission close out plug (1).



14. Place NEW O-rings over the transmission fluid cooler pipes.
15. Install the transmission fluid cooler pipes (1) to the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Replacement.



16. Install the oxygen sensor wiring harness connector (2) from the transmission.
17. Install the wiring harness retainers (1) to the transmission.
18. Connect the transmission wiring harness connector (5) to the transmission by rotating the locking latch clockwise.



19. Install the transmission vent hose to the retaining clips (6) on the transmission support.



20. Install the shift linkage to the transmission.
21. Install the transmission manual shift shaft nut and tighten to 15 N·m (11 lb ft).
22. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement.
23. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
24. Install the exhaust system. Refer to Exhaust System Replacement.
25. Lower the vehicle.
26. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement.
27. Check the transmission fluid level and fill if necessary. Refer to Transmission Fluid Check.
28. Adjust the shift control linkage. Refer to Shift Control Linkage Adjustment.

Complete the following procedure after the transmission is installed in the vehicle:

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. While the engine continues to idle, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Inspect for fluid leaks while the engine is idling.
5. Perform a final inspection for the proper fluid level.
6. Lower the vehicle.
7. Calibrate the transmission control module (TCM). Refer to Control Module References.

Note: It is recommended that transmission adaptive pressure (TAP) information be reset.

Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.
8. Reset the TAP values. Refer to Transmission Adaptive Functions.
9. Road test the vehicle.