Installation Procedure
- Note the new transmission unique number (TUN).
- Support the transmission with a suitable transmission jack.
Raise the transmission (1) into place.
Remove the DT-21366 Converter Holding Strap (1).
- NOTE:
The torque converter must rotate freely by hand.
Slide the transmission (1) straight onto the locating pins while lining up the marks on the flexplate and the torque converter.
- CAUTION:
Refer to Fastener Caution .
Install and tighten the transmission stud (1) and the transmission bolt (2). Fastener Specifications
Transmission Stud (1) - Install and tighten [2x] - Fastener Specifications
Transmission Stud (1) - Install and tighten [4x] - Fastener Specifications
Transmission Bolt (1) - Install and tighten - Fastener Specifications
Install the fuel lines with the fuel cooler (3) as necessary.
- Fuel Feed and Return Front Hose Bracket Nut (1) - Install and tighten - Fastener Specifications
Fuel Cooler Bolt (2) - Install and tighten - Fastener Specifications
- Fuel Cooler Support Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
Retainer (2) - Remove
Install the transmission vent tube (2).
- Install the 2 transmission vent hose retainers (1).
Engine Wiring Harness Channel (1) - Install
Connect the transmission wiring harness connector (1).
- Position the wiring harness then install the 2 wiring harness retainers (2).
Transfer Case Adapter Gasket (3) - Install NEW
- Transfer Case (2) - Install
- Transfer Case Nut (1) - Install and tighten [6x] - Fastener Specifications
- Connect the wiring harness retainers.
- Remove the transmission jack from the transfer case.
Transfer Case Vent Hose (1) - Install
Reposition the wiring harness and install the wiring harness retainer (3) in to the transfer case.
- Connect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
- Connect the transfer case two/four wheel drive actuator electrical connector (1).
Transmission Heat Shield (3) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Transmission Heat Shield Bolt (2) - Install and tighten - Fastener Specifications
- Transmission Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Connect the wiring harness retainers.
Exhaust Front Bracket (2) - Install
- Catalytic Converter Brace Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Connect the wiring harness retainers.
Transmission Mount (2) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Transmission Mount Bolt (1) - Install and tighten [2x] - Fastener Specifications
Raise the transmission into place.
- Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (2) - Install [4x]
- Transmission Support Crossmember Nut (1) - Install and tighten [4x] - Fastener Specifications
Transmission Mount Nut (1) - Install and tighten [2x] - Fastener Specifications
- Remove the support from the transmission.
Automatic Level Control Air Supply Reservoir (2) - Install
- Install the 3 automatic level control air compressor bolts (1) and tighten. Fastener Specifications
Install the chassis wire harness clip (1) to the automatic level control air supply reservoir.
Install the air line (2) and clip the 2 air line retainers (1).
Install the wiring harness as necessary and connect the 4 wiring harness retainers (3).
Install the EN-52579 Crankshaft Rotator (1).
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Using the EN-52579 Crankshaft Rotator, rotate the crankshaft balancer bolt clockwise ONLY, to align the transmission torque converter bolts with the starter opening.
- Transmission Torque Converter Bolt (1) - Install and tighten [6x] - Fastener Specifications
Remove the EN-52579 Crankshaft Rotator (1).
Install the engine front cover (1) from the bottom of the vehicle.
{with RC1} Underbody Splash Shield (1) - Install
Underbody Splash Shield Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Underbody Splash Shield Bolt (2) - Install and tighten [4x] - Fastener Specifications
{with WTX} Front Bumper Fascia Extension (4) - Install
- Install wiring harness retainers as needed.
- Front Bumper Fascia Extension Bolt (3) @ Underbody Skid Shield - Install and tighten [2x] - Fastener Specifications
- Front Bumper Fascia Extension Bolt (2) - Install and tighten [4x] - Fastener Specifications
Front Bumper Fascia Extension (1) - Install
Front Bumper Fascia Extension Bolt (2) - Install and tighten [8x] - Fastener Specifications
- Front Bumper Fascia Air Deflector Bolt (1) - Install and tighten [10x] - Fastener Specifications
{If equipped} Retainer Clip (1) - Engage
Transmission Fluid Cooler Pipe Seal (2) - Install NEW [2x]
- Transmission Fluid Cooler Inlet and Outlet Pipe (1) - Install
Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
- Uncap the fittings and unplug the holes of the transmission.
Reposition the fuel heater inlet and outlet bracket.
- Fuel Heater Inlet and Outlet Bolt (1) @ Transmission - Install and tighten - Fastener Specifications
Reposition the fuel heater inlet and outlet bracket.
- Fuel Heater Inlet and Outlet Nut (1) @ Transmission - Install and tighten - Fastener Specifications
Uncap the fittings and unplug the holes of the transmission.
- Transmission Fluid Cooler Seal (5) - Install NEW
- Remove the suitable strap or wire then reposition the transmission fluid cooling exchanger with automatic transmission fluid cooler inlet and outlet pipes (4) onto the transmission as necessary.
- Automatic Transmission Fluid Cooling Exchanger Nut (3) - Install and tighten - Fastener Specifications
- Transmission Fluid Cooler Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Install and tighten [2x] - Fastener Specifications
Propeller Shaft (1) - Install
Align the reference marks made between the differential drive pinion gear yoke and the propeller shaft.
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Install the 4 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications
Apply a thin layer of grease to the splines of the transfer case front output shaft (1). Adhesives, Fluids, Lubricants, and Sealers
- Loosely install a NEW transfer case front output shaft boot clamp (2) to the transfer case front output shaft boot groove.
- Align the reference marks made between the transfer case front output shaft and the front axle propeller shaft.
- Front Axle Propeller Shaft (3) - Install
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
- Front Axle Propeller Shaft Washer (3) - Install [3x]
- Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications
Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the transfer case front output shaft.
- Using the DT-35910 Drive Axle Seal Clamp Pliers (2), crimp the transfer case front output shaft boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
- Partially lower the vehicle.
Install the starter (1) through the wheel well.
Electrical Connector (1) - Connect
Starter Bolt (1) - Install and tighten [3x] - Fastener Specifications
Starter Solenoid Cable (3) - Install
- Starter Solenoid Cable Nut (1) - Install and tighten - Fastener Specifications
- Wiring Harness Conduit Nut (2) - Install and tighten - Fastener Specifications
Starter Heat Shield (1) - Install
- NOTE:
Components removed for graphic clarity.
Engage the starter heat shield (2) into the retainer (1).
- Starter Heat Shield Bolt (3) - Install and tighten [2x] - Fastener Specifications
Chassis Wiring Harness (4) - Install
- Install the positive battery cable retainers to the chassis wiring harness front bracket.
- Chassis Front Wiring Harness Bracket Bolt - Front (3) - Install and tighten - Fastener Specifications
- Chassis Front Wiring Harness Bracket Bolt - Rear (1) - Install and tighten - Fastener Specifications
- Chassis Wiring Harness Front Bracket Retainer (2) - Install [2x]
Exhaust System Front Gasket (2) - Install NEW
- Nitrogen Oxides Catalytic Converter (1) - Install
Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Brace Bracket (3) - Install
- Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) - Install
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Front Pipe Nut (1) @ Catalytic Converter Brace Bracket - Install and tighten [2x] - Fastener Specifications
Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Coat the threads of the exhaust particulate matter sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Using a suitable tool, install and tighten the exhaust particulate matter sensor (1). Fastener Specifications
Coat the threads of the position 3 nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Using a suitable tool, install and tighten the position 3 nitrogen oxides sensor (1). Fastener Specifications
Coat the threads of the position 2 nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Using a suitable tool, install and tighten the position 2 nitrogen oxides sensor (1). Fastener Specifications
Using a suitable tool, install and tighten the position 3 exhaust gas temperature sensor (1). Fastener Specifications
{If equipped} Transfer Case Skid Shield (2) - Install
- {If equipped} Transfer Case Skid Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Partially lower the vehicle.
- Front Wheelhouse Liner - Right Side - Install - Front Wheelhouse Liner Replacement
Push down and rearward on the engine front cover (2) to engage the 5 retaining grommets to the ball studs.
- Engine Front Cover Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Left side shown, right side similar.
Front End Sheet Metal Diagonal Brace - Left Side and Right Side (2) - Install [2x]
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front End Sheet Metal Diagonal Brace Bolt - Left Side and Right Side (1) - Install and tighten [4x] - Fastener Specifications
Intake Air Splash Shield (2) - Install
- Intake Air Baffle Retainer (1) - Install [9x]
Hood Secondary Latch Release Handle (2) - Install
- Hood Latch Actuator Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Oil Filler Cap - Remove
Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Fill the transmission to the proper level with NEW transmission fluid. Transmission Fluid Fill Procedure
- Inspect for Leaks
- Perform the solenoid valve characterization. Q77 Transmission Control Solenoid Valve Characterization Programming
- Pressure regulating solenoid replacement
- Valve body repair or replacement
- Any service/repair in response to a shift quality concern
- Any internal transmission service, repair, overhaul, or replacement
- Torque converter replacement
- TCM replacement
- Transmission assembly replacement
- Perform the service fast learn procedure. Transmission Service Fast Learn Procedure
- Take the system out of service mode.
For proper alignment of all transmission torque converter bolts, install the first transmission torque converter bolt in the oval shaped hole.
Refer to Component Fastener Tightening Caution .
The Service Fast Learn procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set:
The service fast learn procedure must be performed when any of the following repairs has been made to the transmission.