Installation

Transmission - Four Wheel Drive (4WD)









Installation

NOTICE: Prior to installation of the transmission, the torque converter pilot hub must be lubricated with multi-purpose grease or damage to the torque converter or the engine crankshaft can occur.

1. Lubricate the torque converter pilot hub with multi-purpose grease.





2. Install the Torque Converter Retainer.





3. NOTICE: The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.

NOTE: Make sure that the transmission jack makes contact on the outer ribs of the transmission fluid pan.

NOTE: Make sure that the transmission is securely fastened to the transmission jack.

Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.

4. Remove the Torque Converter Retainer.





5. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.

With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.

6. NOTE: Install the transmission-to-engine bolts in their correct locations.

NOTE: The top 2 transmission-to-engine bolts need to be installed prior to installing the rest of the bolts.

Install 6 of the remaining 7 transmission-to-engine bolts.

- Tighten to 48 Nm (35 lb-ft).





7. Connect the transmission vehicle harness connector by pushing it in and twisting the outer shell to lock it in place.





8. Attach the transmission vehicle harness to the top of the transmission.





9. Install the starter motor and the 3 starter motor bolts.
- Tighten to 26 Nm (19 lb-ft).





10. Install the ground wire on the stud and install the ground wire nut.
- Tighten to 23 Nm (17 lb-ft).





11. Install the starter motor electrical connectors.

1. Tighten to 12 Nm (106 lb-in).

2. Tighten to 6 Nm (53 lb-in).





12. Install the plastic starter motor electrical connector cap.





13. Position the transmission fluid cooler tubes in place and install the transmission fluid cooler tube bracket front stud bolt nut.
- Tighten to 27 Nm (20 lb-ft).





14. Align the transmission fluid cooler tube bracket and install the remaining transmission-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





15. NOTE: Inspect the case to make sure that the old transmission fluid cooler tube O-rings are not stuck in the case.

NOTE: Install new transmission fluid cooler tube O-rings on the ends of the transmission fluid cooler tubes prior to installing.

Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.





16. Install the transmission fluid cooler tube bracket bolt.
- Tighten to 23 Nm (17 lb-ft).





17. Install 4 new flexplate-to-torque converter nuts.
- Tighten to 35 Nm (26 lb-ft).





18. Install the rubber access plug.





19. Install the flexplate inspection cover and the flexplate inspection cover bolts.
- Tighten to 35 Nm (26 lb-ft).





20. Install the selector lever cable bracket and selector lever cable bracket bolts.
- Tighten to 48 Nm (35 lb-ft).





21. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.

NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever. Pull back on the selector lever cable end to make sure that the selector lever cable end is securely installed onto the manual control lever.

With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever and move the locking tab down.

1. Selector lever cable end

2. Locking tab

- Listen for the audible click.

- Pull back on the selector lever cable to make sure that it is securely installed.





22. Install selector lever cable heat shield.





23. Install the fuel line bracket and the rear fuel line bracket bolt.
- Tighten to 25 Nm (18 lb-ft).





24. NOTICE: Prior to Installation, Inspect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) wiring harness for damage.

Position the dual catalytic converter Y-pipe in place and install the dual catalytic converter Y-pipe bolts and new nuts.

- Tighten to 40 Nm (30 lb-ft).





25. NOTE: LH shown, RH similar.

Install new LH and RH exhaust flange nuts.

- Tighten to 40 Nm (30 lb-ft).





26. NOTE: LH shown, RH similar.

Connect the RH and LH HO2S connectors and the CMS connectors.





27. Install the transmission support crossmember.

28. Position a jackstand under the transmission, and remove the transmission jack.





29. Install the transfer case. For additional information, refer to Transfer Case.

30. Connect the battery ground cable. For additional information, refer to Battery.

31. Verify that the selector lever cable is correctly adjusted. For additional information, refer to Automatic Transmission/Transaxle.

32. Program the Transmission Control Module (TCM) with the latest calibration.

33. Fill the transmission with clean transmission fluid. For additional information, refer to Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill.