Transmission Replacement 7.2L with AT545

Removal Procedure

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.
3. Drain the transmission oil. Refer to Transmission Fluid Pan and Filter Replacement .
4. Cover the oil pan opening in order to prevent the entry of foreign material.



5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .



6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Oil Cooler Line Replacement .



7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
8. Remove the modulator from the transmission. Refer to Transmission Modulator Replacement .
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

12. Disconnect the parking brake linkage, if equipped. Refer to Park Brake Cable Replacement in Park Brake.




NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts:

•	If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.

•	If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.

14. Remove the torque converter from the engine flex plate or the transmission flex plate.

14.1.

Remove the flywheel housing access cover

14.2.

Turn the flex plates using a pry bar in order to align the engine flex plate bolt with the access hole.

14.3.

Remove the bolts or the nuts.

15. Remove the transmission rear support beam, if equipped.
16. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing.
17. Support the rear of the engine on a jack stand.



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



19. Remove the transmission from the engine.

19.1.

Lower the transmission.

19.2.

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

19.3.

Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.

19.4.

Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.

Installation Procedure

NOTICE: Carefully inspect the transmission and the surrounding area to be sure no lines, hoses or wires will interfere with the transmission installation. When raising and moving the transmission, do not let the torque converter slip off the shaft. The transmission or torque converter can be damaged.

1. Install the transmission.

1.1.	Using a transmission dolly that can support a load of at least 349 kg (750 lb), lift the transmission into place.

1.2.	Move the transmission forward.

1.3.	Align the torque converter with the pilot hole in the engine flex plate or the transmission flex plate and the mounting holes in the flex plate.

1.4.	Install the torque converter to the engine flex plate bolts or the nuts finger tight.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the transmission to the engine with the bolts.

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




3. Install the torque converter to the flywheel with the bolts.
4. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.

Tighten
Tighten the torque converter to flywheel bolts to 67 N·m (49 lb ft).

5. Install the flywheel housing access cover.
6. Install the transmission rear support beam, if equipped.
7. Install the transmission rear support beam to transmission nuts.

Tighten
Tighten the support beam nuts to 105 N·m (77 lb ft).

8. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Engine Mount Replacement .
9. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.

Tighten
Tighten the cushion to the bracket nuts to 45 N·m (33 lb ft).

10. Install the cushion to support nuts and the shims, as needed.

Tighten
Tighten the cushion to support nuts to 31 N·m (23 lb ft).

11. Connect the parking brake linkage. Refer to Park Brake Cable Replacement in Park Brake.



12. Connect the oil cooler lines to the transmission. Refer to Transmission Oil Cooler Line Replacement .



13. Install the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .
14. Connect the speedometer sensor harness.
15. Install the propeller shaft to the transmission. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

16. Install the modulator to the transmission. Refer to Transmission Modulator Replacement .



17. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
18. Connect any additional lines, hose, or wires, as required.
19. Fill the transmission with oil. Refer to Fluid Capacity Specifications .

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.

20. Connect the negative battery cable.
21. Check the transmission oil level. Refer to Transmission Fluid Check .
22. Remove the wheel blocks.

Transmission Replacement 6.0L/7.0L with AT545

Removal Procedure

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.
3. Drain the transmission oil. Refer to Transmission Fluid Pan and Filter Replacement .
4. Cover the oil pan opening in order to prevent the entry of foreign material.



5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .



6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Oil Cooler Line Replacement .



7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
8. Remove the modulator from the transmission. Refer to Transmission Modulator Replacement .
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

12. Disconnect the parking brake linkage, if equipped. Refer to Park Brake Cable Replacement in Park Brake.




NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts:

•	If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.

•	If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.

14. Remove the torque converter from the engine flex plate or the transmission flex plate.

14.1.

Remove the flywheel housing access cover

14.2.

Turn the flex plates using a pry bar in order to align the engine flex plate bolt with the access hole.

14.3.

Remove the bolts or the nuts.

15. Remove the transmission rear support beam, if equipped.
16. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing.
17. Support the rear of the engine on a jack stand.
18. Remove the bolts securing the transmission to the engine.



19. Remove the transmission from the engine.

19.1.

Lower the transmission.

19.2.

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

19.3.

Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.

19.4.

Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.

Installation Procedure

NOTICE: Carefully inspect the transmission and the surrounding area to be sure no lines, hoses or wires will interfere with the transmission installation. When raising and moving the transmission, do not let the torque converter slip off the shaft. The transmission or torque converter can be damaged.

1. Install the transmission.

1.1.	Using a transmission dolly that can support a load of at least 349 kg (750 lb), lift the transmission into place.

1.2.	Move the transmission forward.

1.3.	Align the torque converter with the pilot hole in the engine flex plate or the transmission flex plate and the mounting holes in the flex plate.

1.4.	Install the torque converter to the engine flex plate bolts or nuts finger tight.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the transmission to the engine with the bolts.

Tighten
Tighten the transmission to engine bolts to 67 N·m (49 lb ft).

3. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.

Tighten
Tighten the torque converter to flywheel bolts to 67 N·m (49 lb ft).

4. Install the flywheel housing access cover.
5. Install the transmission rear support beam, if equipped.
6. Install the transmission rear support beam to transmission nuts.

Tighten
Tighten the support beam nuts to 105 N·m (77 lb ft).

7. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Refer to Rear Engine Mount Replacement in Engine Mechanical -- 7.2L Engine (Caterpillar).
8. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.

Tighten
Tighten the cushion to the bracket nuts to 45 N·m (33 lb ft).

9. Install the cushion to support nuts and the shims, as needed.

Tighten
Tighten the cushion to support nuts to 31 N·m (23 lb ft).

10. Connect the parking brake linkage. Refer to Park Brake Cable Replacement in Park Brake.



11. Connect the oil cooler lines to the transmission. Refer to Transmission Oil Cooler Line Replacement .



12. Install the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .
13. Connect the speedometer sensor harness.
14. Install the propeller shaft to the transmission. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

15. Install the modulator to the transmission. Refer to Transmission Modulator Replacement .



16. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
17. Connect any additional lines, hose, or wires, as required.
18. Fill the transmission with oil. Refer to Fluid Capacity Specifications .

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.

19. Connect the negative battery cable.
20. Check the transmission oil level. Refer to Transmission Fluid Check .
21. Remove the wheel blocks.

Transmission Replacement 6.0L/7.0L with MT643/MT653

Removal Procedure

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.
3. Drain the transmission oil. Refer to Transmission Fluid Pan and Filter Replacement .
4. Cover the oil pan opening in order to prevent the entry of foreign material.



5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .



6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Oil Cooler Line Replacement .



7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
8. Remove the modulator from the transmission. Refer to Transmission Modulator Replacement .
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

12. Disconnect the parking brake linkage, if equipped. Refer to Park Brake Cable Replacement in Park Brake.




NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts:

•	If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.

•	If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.

14. Remove the torque converter from the engine flex plate or the transmission flex plate.

14.1.

Remove the flywheel housing access cover.

14.2.

Remove the engine oil filter.

14.3.

Turn the flex plates using a pry bar in order to align the engine flex plate bolt with the access hole.

14.4.

Remove the bolts or the nuts.

15. Remove the transmission rear support beam, if equipped.
16. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing. Refer to Engine Mount Replacement in Engine Mechanical.
17. Support the rear of the engine on a jack stand.



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



19. Remove the transmission from the engine.

19.1.

Lower the transmission.

19.2.

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

19.3.

Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.

19.4.

Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.

Installation Procedure

NOTICE: Carefully inspect the transmission and the surrounding area to be sure no lines, hoses or wires will interfere with the transmission installation. When raising and moving the transmission, do not let the torque converter slip off the shaft. The transmission or torque converter can be damaged.

1. Install the transmission.

1.1.	Using a transmission dolly that can support a load of at least 349 kg (750 lb), lift the transmission into place.

1.2.	Move the transmission forward.

1.3.	Align the torque converter with the pilot hole in the engine flex plate or the transmission flex plate and the mounting holes in the flex plate

1.4.	Install the torque converter to the engine flex plate bolts or the nuts finger tight.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the transmission to the engine with the bolts.

Tighten
Tighten the transmission to engine bolts to 50 N·m (37 lb ft).




3. Install the torque converter to the flywheel with the bolts.
4. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.

Tighten
Tighten the torque converter to flywheel bolts to 50 N·m (37 lb ft).

5. Install the flywheel housing access cover.
6. Install the transmission rear support beam, if equipped.
7. Install the transmission rear support beam to transmission nuts.

Tighten
Tighten the support beam nuts to 105 N·m (77 lb ft).

8. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Refer to Engine Mount Replacement in Engine Mechanical -- 6.0L, 7.0L Engine.
9. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.

Tighten
Tighten the cushion to the bracket nuts to 45 N·m (33 lb ft).

10. Install the cushion to support nuts and the shims, as needed.

Tighten
Tighten the cushion to support nuts to 31 N·m (23 lb ft).

11. Connect the parking brake linkage. Refer to Park Brake Cable Replacement in Park Brake.



12. Connect the oil cooler lines to the transmission. Refer to Transmission Oil Cooler Line Replacement .



13. Install the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .
14. Connect the speedometer sensor harness.
15. Install the propeller shaft to the transmission. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

16. Install the modulator to the transmission. Refer to Transmission Modulator Replacement .



17. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
18. Connect any additional lines, hose, or wires, as required.
19. Fill the transmission with oil. Refer to Fluid Capacity Specifications .

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.

20. Connect the negative battery cable.
21. Check the transmission oil level. Refer to Transmission Fluid Check .
22. Remove the wheel blocks.

Transmission Replacement 7.2L with MD3080/MD3580

Removal Procedure

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.
3. Drain the transmission oil. Refer to Transmission Fluid Pan and Filter Replacement .
4. Cover the oil pan opening in order to prevent the entry of foreign material.



5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .



6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Oil Cooler Line Replacement .
7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
8. Remove the modulator from the transmission. Refer to Transmission Modulator Replacement .
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

12. Disconnect the parking brake linkage, if equipped. Refer to Park Brake Cable Replacement in Park Brake.




NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts:

•	If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.

•	If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.

14. Remove the torque converter from the engine flex plate or the transmission flex plate.

14.1.

Remove the flywheel housing access cover.

14.2.

Turn the flex plates using a pry bar in order to align the engine flex plate bolt with the access hole.

14.3.

Remove the bolts or the nuts.

15. Remove the transmission rear support beam, if equipped.
16. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing. Refer to Engine Mount Replacement in Engine Mechanical.
17. Support the rear of the engine on a jack stand.
18. Remove the bolts securing the transmission to the engine.



19. Remove the transmission from the engine.

19.1.

Lower the transmission.

19.2.

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

19.3.

Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.

19.4.

Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.

Installation Procedure

NOTICE: Carefully inspect the transmission and the surrounding area to be sure no lines, hoses or wires will interfere with the transmission installation. When raising and moving the transmission, do not let the torque converter slip off the shaft. The transmission or torque converter can be damaged.

1. Install the transmission.

1.1.	Using a transmission dolly that can support a load of at least 349 kg (750 lb), lift the transmission into place.

1.2.	Move the transmission forward.

1.3.	Align the torque converter with the pilot hole in the engine flex plate or the transmission flex plate and the mounting holes in the flex plate.

1.4.	Install the torque converter to the engine flex plate bolts or the nuts finger tight.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the transmission to the engine with the bolts.

Tighten
Tighten the transmission to engine bolts to 58 N·m (43 lb ft).

3. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.

Tighten
Tighten the torque converter to flywheel bolts to 45 N·m (33 lb ft).

4. Install the flywheel housing access cover.
5. Install the transmission rear support beam, if equipped.
6. Install the transmission rear support beam to transmission nuts.

Tighten
Tighten the support beam nuts to 105 N·m (77 lb ft).

7. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Engine Mount Replacement in Engine Mechanical -- 7.2L Engine (Caterpillar).
8. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.

Tighten
Tighten the cushion to the bracket nuts to 45 N·m (33 lb ft).

9. Install the cushion to support nuts and the shims, as needed.

Tighten
Tighten the cushion to support nuts to 31 N·m (23 lb ft).

10. Connect the parking brake linkage. Refer to Park Brake Cable Replacement in Park Brake.



11. Connect the oil cooler lines to the transmission. Refer to Transmission Oil Cooler Line Replacement .



12. Install the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .
13. Connect the speedometer sensor harness.
14. Install the propeller shaft to the transmission. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

15. Install the modulator to the transmission. Refer to Transmission Modulator Replacement .



16. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
17. Connect any additional lines, hose, or wires, as required.
18. Fill the transmission with oil. Refer to Fluid Capacity Specifications .

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.

19. Connect the negative battery cable.
20. Check the transmission oil level. Refer to Transmission Fluid Check .
21. Remove the wheel blocks.

Transmission Replacement 7.0L with AT545

Removal Procedure

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.
3. Drain the transmission oil. Refer to Transmission Fluid Pan and Filter Replacement .
4. Cover the oil pan opening in order to prevent the entry of foreign material.



5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .



6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Oil Cooler Line Replacement .



7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
8. Remove the modulator from the transmission. Refer to Transmission Modulator Replacement .
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

12. Disconnect the parking brake linkage, if equipped. Refer to Park Brake Cable Replacement in Park Brake.




NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts:

•	If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.

•	If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.

14. Remove the torque converter from the engine flex plate or the transmission flex plate.

14.1.

Remove the flywheel housing access cover

14.2.

Remove the engine oil filter.

14.3.

Turn the flex plates using a pry bar in order to align the engine flex plate bolt with the access hole.

14.4.

Remove the bolts or the nuts.

15. Remove the transmission rear support beam, if equipped.
16. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing.
17. Support the rear of the engine on a jack stand.



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



19. Remove the transmission from the engine.

19.1.

Lower the transmission.

19.2.

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

19.3.

Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.

19.4.

Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.

Installation Procedure

NOTICE: Carefully inspect the transmission and the surrounding area to be sure no lines, hoses or wires will interfere with the transmission installation. When raising and moving the transmission, do not let the torque converter slip off the shaft. The transmission or torque converter can be damaged.

1. Install the transmission.

1.1.	Using a transmission dolly that can support a load of at least 349 kg (750 lb), lift the transmission into place.

1.2.	Move the transmission forward.

1.3.	Align the torque converter with the pilot hole in the engine flex plate or in the transmission flex plate and the mounting holes in the flex plate.

1.4.	Install the torque converter to the engine flex plate bolts or the nuts finger tight.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the transmission to the engine with the bolts.

Tighten
Tighten the transmission to engine bolts to 67 N·m (49 lb ft).




3. Install the torque converter to the flywheel with the bolts.
4. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.

Tighten
Tighten the torque converter to flywheel bolts to 56 N·m (41 lb ft).

5. Install the flywheel housing access cover.
6. Install the transmission rear support beam, if equipped.
7. Install the transmission rear support beam to transmission nuts.

Tighten
Tighten the support beam nuts to 105 N·m (77 lb ft).

8. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Engine Mount Replacement in Engine Mechanical -- 6.0L and 7.0L Engine.
9. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.

Tighten
Tighten the cushion to the bracket nuts to 45 N·m (33 lb ft).

10. Install the cushion to support nuts and the shims, as needed.

Tighten
Tighten the cushion to support nuts to 31 N·m (23 lb ft).

11. Connect the parking brake linkage. Refer to Park Brake Cable Replacement in Park Brake.



12. Connect the oil cooler lines to the transmission. Refer to Transmission Oil Cooler Line Replacement .



13. Install the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .
14. Connect the speedometer sensor harness.
15. Install the propeller shaft to the transmission. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

16. Install the modulator to the transmission. Refer to Transmission Modulator Replacement .



17. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
18. Connect any additional lines, hose, or wires, as required.
19. Fill the transmission with oil. Refer to Fluid Capacity Specifications .

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.

20. Connect the negative battery cable.
21. Check the transmission oil level. Refer to Transmission Fluid Check .
22. Remove the wheel blocks.

Transmission Replacement 7.2L with MD3060/3560

Removal Procedure

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.
3. Drain the transmission oil. Refer to Transmission Fluid Pan and Filter Replacement .
4. Cover the oil pan opening in order to prevent the entry of foreign material.



5. Remove the transmission oil level indicator and the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .



6. Disconnect the oil cooler lines from the transmission. Refer to Transmission Oil Cooler Line Replacement .



7. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement .
8. Remove the modulator from the transmission. Refer to Transmission Modulator Replacement .
9. Disconnect the wiring harness and the connectors from the transmission.
10. Disconnect the speedometer sensor harness from the transmission.
11. Remove the propeller shaft. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

12. Disconnect the parking brake linkage, if equipped. Refer to Park Brake Cable Service/Adjustment in Park Brake.




NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

NOTICE: Carefully inspect the transmission and the surrounding areas to be sure no lines, hoses or wires will interfere with the transmission removal. In order to avoid damage to the transmission or the torque converter, support the transmission with a dolly jack. Do not let the torque converter fall.

13. Determine what type of front engine mount is on the vehicle and take the following steps when removing the rear engine mounting bolts.

•	If the mount is a single cushion, center mount, support the engine with an overhead hoist during the transmission replacement in order to prevent tipping.

•	If the rear engine mounting bolts are not attached to the engine flywheel housing, support the rear of the engine on a jack stand.

14. Remove the torque converter from the engine flex plate or the transmission flex plate.

14.1.

Remove the flywheel housing access cover

14.2.

Turn the flex plates using a pry bar in order to align the engine flex plate bolt with the access hole.

14.3.

Remove the bolts or the nuts.

15. Remove the transmission rear support beam, if equipped.
16. Remove the rear engine mounting bolts, if the mounts are not attached to the engine flywheel housing. Refer to Engine Mount Replacement in Engine Mechanical.
17. Support the rear of the engine on a jack stand.
18. Remove the bolts securing the transmission to the engine.



19. Remove the transmission from the engine.

19.1.

Lower the transmission.

19.2.

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

19.3.

Position the dolly in order to ensure the transmission oil pan does not support the weight of the transmission.

19.4.

Fasten a safety chain over the top of the transmission. Fasten the chain on both sides of the dolly.

Installation Procedure

NOTICE: Carefully inspect the transmission and the surrounding area to be sure no lines, hoses or wires will interfere with the transmission installation. When raising and moving the transmission, do not let the torque converter slip off the shaft. The transmission or torque converter can be damaged.

1. Install the transmission.

1.1.	Using a transmission dolly that can support a load of at least 349 kg (750 lb), lift the transmission into place.

1.2.	Move the transmission forward.

1.3.	Align the torque converter with the pilot hole in the engine flex plate or the transmission flex plate and the mounting holes in the flex plate.

1.4.	Install the torque converter to the engine flex plate bolts or the nuts finger tight.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the transmission to engine bolts.

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

3. Turn the engine flex plate using a pry bar in order to install the torque converter to flywheel bolts.

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

4. Install the flywheel housing access cover.
5. Install the transmission rear support beam, if equipped.
6. Install the transmission rear support beam to transmission nuts.

Tighten
Tighten the support beam nuts to 105 N·m (77 lb ft)

7. Install the rear engine mount bolts, if the mounts are attached to the transmission case. Refer to Rear Engine Mount Replacement in Engine Mechanical -- 6.6L Engine (Caterpillar).
8. Install the cushion, the bolts, and the washers to the frame bracket, if equipped.

Tighten
Tighten the cushion to the bracket nuts to 45 N·m (33 lb ft).

9. Install the cushion to support nuts and the shims, as needed.

Tighten
Tighten the cushion to support nuts to 31 N·m (23 lb ft).

10. Connect the parking brake linkage. Refer to Park Brake Cable Replacement in Park Brake.



11. Connect the oil cooler lines to the transmission. Refer to Transmission Oil Cooler Line Replacement .



12. Install the oil level indicator tube. Refer to Transmission Oil Level Indicator Tube Replacement .
13. Connect the speedometer sensor harness.
14. Install the propeller shaft to the transmission. Refer to the necessary procedure:

•	One-Piece Propeller Shaft Replacement

•	Two-Piece Propeller Shaft Replacement

•	Three-Piece Propeller Shaft Replacement

15. Install the modulator to the transmission. Refer to Transmission Modulator Replacement .



16. Connect the shift cable to the transmission. Refer to Shift Cable Replacement .
17. Connect any additional lines, hose, or wires, as required.
18. Fill the transmission with oil. Refer to Fluid Capacity Specifications .

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.

19. Connect the negative battery cable.
20. Check the transmission oil level. Refer to Transmission Fluid Check .
21. Remove the wheel blocks.