Removal Procedure
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Oil Filler Cap - Remove
Intake Manifold Cover Bolt (1) - Remove
- Intake Manifold Cover (2) - Remove
- Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
Hood Latch Actuator Bolt (1) - Remove [2x]
- Hood Secondary Latch Release Handle (2) - Remove
Intake Air Baffle Retainer (1) - Remove [9x]
- Intake Air Splash Shield (2) - Remove
- NOTE:
Left side shown, right side similar.
Front End Sheet Metal Diagonal Brace Bolt - Left Side and Right Side (1) - Remove [4x]
- Front End Sheet Metal Diagonal Brace - Left Side and Right Side (2) - Remove [2x]
- Front Wheelhouse Liner - Right Side - Remove - Front Wheelhouse Liner Replacement
- NOTE:
Some components not shown for graphic clarity.
Engine Front Cover Bolt (1) - Remove
- Pull forward and upward on the engine front cover (2) to release the 5 retaining grommets from the ball studs.
Exhaust Front Pipe Nut (1) - Remove [2x]
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) - Remove
- Catalytic Converter Brace Bracket (3) - Remove
Using a suitable tool, remove the position 3 exhaust gas temperature sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the position 2 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the position 3 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the exhaust particulate matter sensor (1) from the nitrogen oxides catalytic converter.
Exhaust Pipe Clamp (1) - Loosen
Exhaust Front Pipe Nut (1) - Remove [2x]
Nitrogen Oxides Catalytic Converter (1) - Remove
- Exhaust System Front Gasket (2) - Remove and DISCARD
Chassis Front Wiring Harness Bracket Bolt - Rear (1) - Remove
- Chassis Wiring Harness Front Bracket Retainer (2) - Remove [2x]
- Chassis Front Wiring Harness Bracket Bolt - Front (3) - Remove
- Remove the positive battery cable retainers from the chassis wiring harness front bracket.
- Chassis Wiring Harness (4) - Reposition
- NOTE:
Components removed for graphic clarity.
Starter Heat Shield Bolt (3) - Remove [2x]
- Disengage the starter heat shield (2) from the retainer (1).
Starter Heat Shield (1) - Remove
Starter Solenoid Cable Nut (1) - Remove
- Wiring Harness Conduit Nut (2) - Remove
- Starter Solenoid Cable (3) - Remove
Starter Bolt (1) - Remove [3x]
- Reposition the starter (2) to access the electrical connector.
Electrical Connector (1) - Disconnect
Remove the starter (1) through the wheel well.
{If equipped} Transfer Case Skid Shield Bolt (1) - Remove [3x]
- {If equipped} Transfer Case Skid Shield (2) - Remove
- Place a drain pan under the vehicle.
Automatic Transmission Fluid Pan Bolt (1) - Remove [16x]
- Automatic Transmission Fluid Pan (2) - Remove
- Automatic Transmission Fluid Pan Gasket (3) - Remove
- Allow the transmission to drain.
Automatic Transmission Fluid Pan Gasket (3) - Install
- Automatic Transmission Fluid Pan (2) - Install
- Automatic Transmission Fluid Pan Bolt (1) - Install and hand tighten [16x]
- Remove the drain pan.
Transfer Case Front Output Shaft Boot Clamp (1) @ Front Axle Propeller Shaft - Remove and DISCARD
- Reposition the transfer case front output shaft boot (2) and mark a reference point between the front axle propeller shaft and the transfer case front output shaft.
Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
- Front Axle Propeller Shaft Bolt (2) - Remove [6x]
- Front Axle Propeller Shaft Washer (3) - Remove [3x]
Front Axle Propeller Shaft (1) - Remove
Mark the relationship of the propeller shaft to the differential drive pinion gear yoke.
- Rear Propeller Shaft Bolt (1) - Remove [4x]
Propeller Shaft (1) - Remove
Remove the 4 wiring harness retainers (3), then reposition the wiring harness as necessary.
Transmission Mount Nut (1) - Remove [2x]
- Support the transmission with a suitable jack.
Transmission Support Crossmember Nut (1) - Remove [4x]
- Transmission Support Crossmember Bolt (2) - Remove [4x]
Transmission Support Crossmember (1) - Remove
Transmission Mount Bolt (1) - Remove [2x]
- Transmission Mount (2) - Remove
Disconnect the wiring harness retainers.
- Catalytic Converter Brace Bracket Bolt (1) - Remove [2x]
- Exhaust Front Bracket (2) - Remove
Transmission Heat Shield Bolt (2) - Remove
- Transmission Heat Shield Bolt (1) - Remove [2x]
- Transmission Heat Shield (3) - Remove
- Disconnect the wiring harness retainers.
Disconnect the transfer case two/four wheel drive actuator electrical connector (1).
- Disconnect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
- Remove the wiring harness retainer (3) from the transfer case and position the wiring harness out of the way.
Transfer Case Vent Hose (1) - Remove
- Using a suitable transmission jack, support the transfer case.
- Using suitable straps or chains, secure the transfer case to the transmission jack.
Transfer Case Nut (1) - Remove [6x]
- Transfer Case (2) - Remove
- Transfer Case Adapter Gasket (3) - Remove and DISCARD
- Disconnect the wiring harness retainers.
Fuel Heater Inlet and Outlet Nut (1) @ Transmission - Remove
Fuel Heater Inlet and Outlet Bolt (1) @ Transmission - Remove
- Reposition the fuel heater inlet and outlet hoses aside.
Transmission Fluid Cooler Pipe Nut (1) - Remove
Transmission Fluid Cooler Inlet and Outlet Pipe (1) - Reposition
- Transmission Fluid Cooler Pipe Seal (2) - Remove and DISCARD [2x]
- Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Remove [2x]
- Transmission Fluid Cooler Pipe Bolt (2) - Remove
- Automatic Transmission Fluid Cooling Exchanger Nut (3) - Remove
- Reposition the transmission fluid cooling exchanger with automatic transmission fluid cooler inlet and outlet pipes (4) away from the transmission as necessary and secure using a suitable strap or wire.
- Transmission Fluid Cooler Seal (5) - Remove and DISCARD
- Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
{If equipped} Retainer Clip (1) - Disengage
{with RC1} Front Bumper Fascia Skid Plate Bolt (1) - Remove [4x]
{with WTX} Front Bumper Fascia Air Deflector Bolt (1) - Remove [10x]
- Front Bumper Fascia Extension Bolt (2) - Remove [8x]
Pull the front bumper fascia extension (1) rearward and down from the front bumper fascia.
Front Bumper Fascia Extension Bolt (2) - Remove [4x]
- Front Bumper Fascia Extension Bolt (3) @ Underbody Skid Shield - Remove [2x]
- Remove wiring harness retainers as needed.
- Front Bumper Fascia Extension (4) - Remove
Remove the engine front cover (1) from the bottom of the vehicle.
Using the EN-52579 Crankshaft Rotator (1), rotate the crankshaft balancer bolt clockwise ONLY, to align the transmission torque converter bolts with the starter opening.
Repeat the following steps for all transmission torque converter bolts (1) :
- Using the EN-52579 Crankshaft Rotator, rotate the crankshaft balancer clockwise ONLY, to align the transmission torque converter bolt with the starter opening.
- Transmission Torque Converter Bolt (1) - Remove [6x]
Remove the EN-52579 Crankshaft Rotator (1).
- Lower the transmission to gain access to the top and sides of the transmission.
Fuel Feed and Return Front Hose Bracket Nut (1) - Remove
Retainer (2) - Remove
Fuel Cooler Support Bracket Bolt (1) - Remove [2x]
- Fuel Cooler Bolt (2) - Remove
- Reposition the fuel lines with the fuel cooler (3).
Remove the 2 transmission vent hose retainers (1).
- Remove the transmission vent hose. (2)
Disconnect the transmission wiring harness connector (1).
- Remove the 2 wiring harness retainers (2) and reposition the wiring harness as necessary.
- CAUTION:
Carefully remove the engine wiring harness channel from the transmission stud. If the engine wiring harness channel is damaged during removal, replace the engine wiring harness channel. Failure to replace the channel may lead to harness damage.
Carefully remove the engine wiring harness channel (1) from the transmission stud and position aside.
Transmission Stud (1) - Remove [4x]
Remove the transmission stud (1) and the transmission bolt (2).
Transmission Stud (1) - Remove [2x]
Transmission Bolt (1) - Remove
- Pull the transmission straight back.
- WARNING:
The torque converter must be held to the torque converter housing by a retaining device such as shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing personal injury and/or property damage.
Install the DT-21366 Converter Holding Strap (1) onto the transmission bell housing to retain the torque converter.
Automatic Transmission (1) - Remove