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Gearbox/Converter & Transfer Gearbox Assembly - Remove For Access And Refit: Installation

  1. Clean mounting and mating faces.
  2. Remove torque converter retaining plate.
  3. With assistance, carefully fit gearbox to engine. Ensure engagement of torque converter spigot and gearbox housing onto dowels.
  4. Fit 8 Torx bolts securing automatic gearbox to engine, tighten to 45 Nm (33 ft. lbs.)
  5. Clean fluid cooler pipes unions and mating faces.
  6. Position fluid cooler pipe to left hand side of gearbox.
  7. Lubricate fluid cooler sealing washers with transmission fluid, fit banjo bolt to gearbox and tighten to 37 Nm (27 ft. lbs.)
  8. Fit and lubricate new "O" ring to fluid cooler pipe, fit pipe to gearbox and tighten to 37 Nm (27 ft. lbs.).
  9. Position fluid cooler saddle clamp, fit bolt and tighten to 6 Nm (4.4 ft. lbs.)
  10. Fit starter motor and tighten bolts to 45 Nm (33 ft. lbs.).
  11. Fit bolts securing drive plate to torque converter and tighten to 45 Nm (33 ft. lbs.)
  12. Fit grommet to gearbox bell housing.
  13. Fit undertray.
  14. Fit oxygen sensor leads to gearbox casing.
  15. Clean crankshaft sensor and mating face.
  16. Position crankshaft sensor, fit bolt and tighten to 6 Nm (4.4 ft. lbs.)
  17. Position selector cable support bracket to gearbox, fit bolts and tighten to 10 Nm (7 ft. lbs.)
  18. Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 ft. lbs.)
  19. Fit and secure oxygen sensor leads to transfer gearbox.
  20. Connect multiplug to gearbox connector.
  21. Connect multiplug to high/low shift motor.
  22. Raise gearbox on jack.
  23. Fit snubbers.
  24. Fit cross member to mounting, fit nut and bolt but do not tighten at this stage.
  25. Align cross member, fit bolts and tighten to 68 Nm (50 ft. lbs.).
  26. Remove support from gearbox.
  27. Tighten nut and bolt securing mounting to cross member to 100 Nm (74 ft. lbs.).
  28. Fit heat shield and secure with nuts.
  29. Fit rear propeller shaft.
  30. Fit front propeller shaft.
  31. Lower vehicle.
  32. Fit top bell housing Torx bolts and tighten to 25 Nm (18 ft. lbs.)
  33. Fit and secure left hand oxygen sensor lead to gearbox bell housing.
  34. Connect inhibitor switch multiplug.
  35. Fit air intake plenum.
  36. Fit fan to pulley and tighten viscous coupling nut to 40 Nm (30 ft. lbs.).
  37. Connect battery earth lead.
  38. Fill gearbox with fluid.
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