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Service Information: Installation

Fig 1: Measuring Torque Converter Installation Depth
GC0012727Courtesy of DAIMLERCHRYSLER CORP.
1 - TORQUE CONVERTER
2 - TRANSMISSION HOUSING
  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. 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.
  3. Lubricate oil pump seal lip with transmission fluid.
  4. Place torque converter in position on transmission.
    CAUTION: Do not damage oil pump seal or converter hub while inserting torque converter into the front of the transmission.
  5. Align torque converter to oil pump seal opening.
  6. Insert torque converter (1) hub into oil pump. See Fig 1.
  7. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears.
  8. Check converter seating with a scale and straightedge. Surface of converter lugs should be at least 19 mm (3/4 in.) to rear of straightedge when converter is fully seated.
  9. If necessary, temporarily secure converter with C-clamp attached to the converter housing.
    Fig 2: Removing/Installing Transmission to Engine Bolts
    GC0027363Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - TRANSMISSION
    3 - BOLTS
    4 - WIRING HARNESS CLIPS
  10. 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. 
  11. Apply a light coating of Mopar® High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
  12. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
  13. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
  14. Carefully work transmission (2) forward and over engine (1) 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. See Fig 2.
  15. Install two bolts (3) to attach the transmission to the engine.
  16. Install remaining torque converter housing to engine bolts. Tighten to 39 N.m (29 ft.lbs.).
    Fig 3: Removal And Installation Structural Cover
    GC0011809Courtesy of DAIMLERCHRYSLER CORP.
    1 - STRUCTURAL COVER TO ENGINE BOLTS
    2 - STRUCTURAL COVER TO TRANSMISSION BOLTS
    2 - TRANSMISSION TO STRUCTURAL COVER BOLTS
  17. Install rear transmission crossmember. Tighten crossmember to frame bolts to 68 N.m (50 ft.lbs.).
  18. Install rear support to transmission. Tighten bolts to 47 N.m (35 ft.lbs.).
  19. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 N.m (39 ft.lbs.). Tighten the clevis bracket to rear support bolt to 68 N.m (50 ft.lbs.).
  20. Remove engine support fixture.
  21. Install the engine to transmission structutral cover:

    For 3.7L (Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION) .

    For 4.7L (Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION) .

    For 5.7L (Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION) .

    Fig 4: Removing/Installing Shift Cable & Bracket
    GC0027365Courtesy of DAIMLERCHRYSLER CORP.
  22. Connect gearshift cable (3) to the gearshift cable bracket (4) and transmission (1). See Fig 4.
    Fig 5: Removing/Installing Wiring Connector Plug
    GC0012698Courtesy of DAIMLERCHRYSLER CORP.
    1 - PLUG CONNECTOR
    2 - ADAPTER PLUG
  23. Check O-ring on plug connector (1), and replace if necessary. See Fig 5.
  24. Install the plug connector (1) into the adapter plug (2). Turn bayonet lock of the adapter plug (2) clockwise to connect plug connector (1).
    Fig 6: Removing/Installing Torque Converter Bolts
    GC0027366Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - DRIVEPLATE
    3 - TORQUE CONVERTER BOLTS
    CAUTION: 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.
  25. Install all torque converter-to-driveplate bolts (3) by hand. See Fig 6.
  26. Verify that the torque converter is pulled flush to the driveplate. Tighten bolts to 42 N.m (31 ft. lbs.).
    Fig 7: Transmission Mounting, Diesel Engine, and Fill Tube
    GC0027367Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - FILL TUBE
    3 - DIPSTICK
    4 - BOLTS
  27. Install starter motor. (Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION)
  28. Install transmission fill tube (2). See Fig 7.
    Fig 8: Transmission Lines
    GC0027364Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - TRANSMISSION OIL COOLER LINES
  29. Connect cooler lines (2) to transmission (1). See Fig 8.
  30. Install exhaust components.
  31. Install transfer case, if necessary:

    For NV140, (Refer to TRANSMISSION/TRANSAXLE/TRANSFER CASE - INSTALLATION) .

    For NV245, (Refer to TRANSMISSION/TRANSAXLE/TRANSFER CASE - INSTALLATION) .

  32. Align and connect propeller shafts. (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER SHAFT - INSTALLATION)
  33. Adjust gearshift cable if necessary. (Refer to TRANSMISSION/AUTOMATIC - NAG1/GEAR SHIFT CABLE - ADJUSTMENTS) .
  34. Lower vehicle.
  35. Connect negative battery cable.
  36. Fill transmission with the appropriate fluid (Refer to TRANSMISSION/AUTOMATIC - NAG1/FILTER - STANDARD PROCEDURE)  and (Refer to LUBRICATION & MAINTENANCE - FLUID TYPES) .
  37. Verify proper operation.
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