Transmission Replacement MD

Tools Required

J 21366 Converter Holding Strap

Important: The following transmission replacement procedure serves as a guide. In order to provide enough clearance for removal of the transmission, removal of other components may be necessary on some vehicles. Information on the removal of other components are not included in this transmission replacement procedure.

1. Block the wheels.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Fluid Filler Tube and Seal Replacement .
4. Remove the starter. Refer to Starter Motor Replacement



5. Remove the transmission oil cooler lines (1, 2) from the transmission.
6. Plug the transmission oil cooler line and the fittings in the case.



7. Remove the shift cable from the transmission.



8. Remove the wiring harness and disconnect the transmission electrical connectors (1, 2, 3).



9. Remove the fuel line from the fuel line bracket, if equipped.
10. If equipped, disconnect the main electrical connector from the rear of the transmission.



11. If equipped, disconnect the rear electrical connector.



12. If equipped, disconnect the electrical connectors (1, 2, 3) from the sensors.
13. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement , Two-Piece Propeller Shaft Replacement or Three-Piece Propeller Shaft Replacement in Propeller Shaft.



14. If equipped, remove the parking brake cable from the brake drum.



15. If equipped, remove the flywheel housing access cover.
16. Turn the flex plate using a pry bar or the engine at the harmonic balancer, in order to align the torque convertor bolts with the access hole or the starter hole.
17. Mark the flywheel and the torque converter or the flex plate relationship for reassembly purposes.



18. Remove the torque convertor bolts.




Important: Support the transmission with a transmission jack that can support a load of at least 349 kg (750 lb).

19. Install the transmission jack to the transmission.
20. Install a safety chain to secure the transmission to the transmission jack.
21. If equipped, remove the transmission rear support. Refer to Transmission Support Replacement .
22. If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine with a suitable lifting/supporting device.
23. Remove the transmission mounting bolts, if the mounts are attached to the engine flywheel housing. Refer to Transmission Mount Replacement .



24. Remove the nuts and the fuel line bracket.



25. Remove the bolts securing the transmission to the engine.



26. Remove the transmission from the engine by sliding the transmission rearward.



27. Install the J 21366 to the transmission converter housing in order to keep the torque converter from sliding off the transmission turbine shaft.
28. Lower and remove the transmission from the vehicle.

Important: Flexplate flatness must be 0.76 millimeter (0.030 inch) Total Indicated Runout (TIR) when measured at 292 millimeter (11.5 inch) diameter. If more, replace the flexplate.

29. If equipped, inspect the flexplate for flatness.

1. Raise the transmission to the engine.
2. If installed, remove the J 21366 from the transmission.
3. Align the transmission with the engine using the alignment dowels located at the rear of the engine.
4. Ensure that the torque converter can be rotated before tightening the studs and the bolts.

Important: DO NOT install the transmission by drawing it to the engine using the studs and the bolts.

5. Ensure that the transmission is flush against the engine.
6. Install the transmission to the engine while aligning the torque converter with the pilot hole in the engine flex plate.

Notice: Refer to Fastener Notice in the Preface section.




7. Install the transmission to engine bolts.

Tighten
Tighten the transmission to engine bolts to 55 N·m (41 lb ft).

8. If equipped, install the fuel line bracket and/or the harness brackets on the transmission mount studs.

Tighten
Tighten the bracket to 30 N·m (22 lb ft).




9. Turn the engine flex plate using a pry bar or engine at the harmonic balancer in order to install the torque converter to flywheel bolts.
10. Install the torque converter to flywheel bolts.

Tighten

•	Tighten the torque converter to flywheel bolts to 67 N·m (49 lb ft) (LCT 1000/2000, 2400).

•	Tighten the torque converter to flywheel bolts to 40 N·m (30 lb ft) (MD Transmissions).

11. Install the flywheel housing access cover.
12. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
13. If equipped, install the transmission rear support beam. Refer to Transmission Support Replacement .
14. Install the transmission mounts to the transmission. Refer to Transmission Mount Replacement .
15. Remove the safety chain and the transmission jack from the transmission.



16. If equipped, install the parking brake cable to the park brake drum.



17. Connect the electrical connectors (1, 2, 3), if equipped.



18. Connect the main electrical connector, if equipped.



19. Install the oil cooler lines (1, 2) to the transmission.



20. Install the oil level indicator tube. Refer to Transmission Fluid Filler Tube and Seal Replacement .
21. Connect the transmission electrical connectors and install the wiring harness to the transmission.
22. If equipped install the fuel line brackets.
23. If equipped install the fuel lines to the fuel line bracket.
24. Install the propeller shaft to the transmission. Refer to One-Piece Propeller Shaft Replacement , Two-Piece Propeller Shaft Replacement or Three-Piece Propeller Shaft Replacement in Propeller Shaft.



25. If equipped, install the shift cable to the transmission.
26. Check and fill the transmission with DEXRON III transmission fluid. Automatic Transmission Fluid and Filter Replacement .
27. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
28. Remove the wheel blocks.

Transmission Replacement 1000, 2000, 2400

Tools Required

Important: If replacing a failed transmission, it is important to reset the transmission control module (TCM) to base calibration and fast adaptive for all shifts. This can be done in one step with a scan tool. If this is not done, the TCM's adaptive values will still be at the settings that it learned for the old transmission, and will be in slow adaptive mode. Under these conditions, it would take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission.

1. Block the wheels.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
4. Remove the transmission fluid level indicator. Refer to Transmission Fluid Filler Tube and Seal Replacement .
5. If required, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.




Important: Rotate the engine clockwise ONLY, rotating the engine counterclockwise may loosen the crankshaft balancer bolt.

7. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts through the starter opening. Have an assistant rotate the engine while aligning the bolts.
8. Remove the torque converter bolts.



9. Disconnect the shift cable from the selector lever ball stud and remove the cable from the bracket.



10. If equipped, remove the fuel line retainer (1) bolts on the left side of the transmission.



11. If equipped, remove the fuel line bracket nut from the converter housing stud.



12. Disconnect the turbine speed sensor (1), input speed sensor (2) and the output speed sensor (3) electrical connectors.
13. Remove the transmission heat shield fasteners and the transmission shield from the transmission.



14. Disconnect the transmission main electrical connector. J 44257 may be used, but is not required.
15. Disconnect the park/neutral position (PNP) switch electrical connector.
16. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement or to Three-Piece Propeller Shaft Replacement in Propeller Shaft.



17. If equipped, remove the parking brake cable from the brake drum.
18. Reposition any wiring harness branches out of the way.
19. Support the transmission with a transmission jack.



20. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other related components.



21. Disconnect the transmission oil cooler lines (1, 2) from the transmission.
22. Plug the transmission oil cooler line fittings in the transmission case.
23. If the vehicle is equipped with a power take off (PTO) unit , disconnect and/or remove any necessary components to facilitate transmission removal.
24. If equipped with rear engine mounts connecting to the transmission, remove the rear engine mounts and support the engine. Refer to Transmission Mount Replacement .
25. If equipped, remove the exhaust hanger bolts and reposition the hanger.
26. If not equipped with rear engine to frame mounts, support the engine using suitable safety stands.
27. If equipped, remove the transmission support. Refer to Transmission Support Replacement .



28. Remove the remaining converter housing bolts and studs.
29. Separate the transmission from the engine.



30. Install J 21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
31. Carefully lower the transmission from the vehicle.
32. Remove the J 21366 .

1. Install J 21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
2. Raise the transmission into place.
3. Remove the J 21366 .

Notice: Refer to Fastener Notice in the Preface section.





Important: Do not install the transmission by drawing it to the engine using the studs and bolts.

4. Align the transmission with the engine using the alignment dowels located at the rear of the engine.

Important: Ensure that the torque converter can be rotated before tightening the bolts and studs.

5. Install the converter housing bolts and studs.

Tighten
Tighten the bolts/studs to 50 N·m (37 lb ft).

6. Position the exhaust hanger and install the bolts.

Tighten
Tighten the bolts to 12 N·m (106 lb in).




7. Install the wire harness/vent tube bracket and nut to the converter housing stud.

Tighten
Tighten the nut to 18 N·m (13 lb ft).

8. If equipped with rear engine mounts mounted to the transmission, install the rear engine mounts. Refer to Transmission Mount Replacement .
9. If equipped with a rear transmission support, install the support. Refer to Transmission Support Replacement .
10. If used, remove the engine supports.



11. Install the transmission fill tube and nuts to the converter housing studs.

Tighten
Tighten the nuts to 18 N·m (13 lb ft).

12. If the vehicle is equipped with a PTO unit, connect and/or install the components at this time.



13. Remove the safety chain from around the transmission.
14. Install the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement or to Three-Piece Propeller Shaft Replacement in Propeller Shaft.
15. Remove the transmission jack.
16. Position the wiring harness branches.
17. Connect the PNP switch electrical connectors.



18. Connect the transmission main electrical connector (2).



19. Connect the output speed sensor (3) electrical connector.
20. Connect the turbine speed sensor (1) and the input speed sensor (2) electrical connectors.



21. If equipped, install the fuel line bracket and nut to the transmission converter housing stud.

Tighten
Tighten the nut to 18 N·m (13 lb ft).




22. If equipped, install the fuel line retainer (1) and bolts to the left side of the transmission.

Tighten
Tighten the bolts to 2.5 N·m (22 lb in).




23. Install the shift cable to the bracket and the selector lever ball stud.



24. Remove the access hole cover (1) on the converter housing in order to rotate the converter and align the first torque converter bolt.



25. If not replacing the torque converter bolts, coat each bolt with Loctite® prior to installation.
26. Install the torque converter bolts.

Tighten
Tighten the bolts to 60 N·m (44 lb ft).

27. Install the converter housing access hole cover.
28. If equipped, install the transmission heat shield and bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

29. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
30. Remove the plugs from the transmission oil cooler fittings.



31. Connect the transmission oil cooler lines (1, 2) to the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
32. If required, lower the vehicle.
33. Connect the negative battery cables . Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
34. Check and fill the transmission with new transmission fluid.
35. Install the transmission fluid level indicator.
36. If a replacement transmission was installed, reset the TCM to base calibration and fast adaptive, using a scan tool.