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Automatic Transmission - 545RFE: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
  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. Verify that the converter hub o-ring is properly installed and is free of any debris. 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. Align converter and oil pump.
  5. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
  6. Check converter seating with steel scale and straightedge. See Fig 1. Surface of converter lugs should be at least 13mm (1/2 in.) to rear of straightedge when converter is fully seated.
  7. Temporarily secure converter with C-clamp.
    Fig 1: Checking Torque Converter Seating - Typical
    GC0005225Courtesy of DAIMLERCHRYSLER CORP.
    1 - SCALE
    2 - STRAIGHTEDGE
  8. Position transmission on jack and secure it with chains.
  9. 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. 
  10. Apply a light coating of Mopar® High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
  11. Raise transmission and align the torque converter with the drive plate and transmission converter housing with the engine block. See Fig 2.
    Fig 2: Removing/Installing Transmission
    GC0005201Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - TRANSMISSION
  12. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.
  13. Carefully work transmission forward and over engine 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.
  14. Install two bolts to attach the transmission to the engine.
  15. Install remaining torque converter housing to engine bolts. Tighten to 68 N.m (50 ft.lbs.).
  16. Install transfer case, if equipped. Tighten transfer case nuts to 35 N.m (26 ft.lbs.).
  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 (35 ft.lbs.). Tighten the clevis bracket to rear support bolt to 68 N.m (50 ft.lbs.).
  20. Remove engine support fixture.
  21. Connect gearshift cable to support bracket and transmission manual lever. See Fig 3.
    Fig 3: Install Shift Cables
    GC0025395Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSFER CASE
    2 - TRANSFER CASE SHIFT CABLE
    3 - TRANSMISSION SHIFT CABLE
    4 - AUTOMATIC TRANSMISSION
    5 - TRANSFER CASE SHIFT CABLE BRACKET
  22. Connect wires to solenoid and pressure switch assembly connector, input and output speed sensors, and line pressure sensor. See Fig 4, Fig 5, Fig 6 and Fig 7. Be sure transmission harnesses are properly routed.
    Fig 4: Locating Transmission Solenoid/TRS Assembly
    GC0005199Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
    Fig 5: Locating Input Speed Sensor
    GC0005198Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - INPUT SPEED SENSOR
    Fig 6: Locating Output Speed Sensor
    GC0005197Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - OUTPUT SPEED SENSOR
    Fig 7: Locating Line Pressure Sensor
    GC0005200Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - LINE PRESSURE SENSOR
    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.
  23. Install torque converter-to-driveplate bolts. Tighten bolts to 31 N.m (270 in. lbs.).
  24. Install starter motor and cooler line bracket.
  25. Connect cooler lines to transmission.
  26. Install transmission fill tube.
  27. Install exhaust components. See Fig 8.
    Fig 8: Removing/Installing Exhaust Flange Bolts
    GC0009448Courtesy of DAIMLERCHRYSLER CORP.
    1 - EXHAUST FLANGE BOLTS
  28. Install the structural dust cover. See Fig 9.
    Fig 9: Transmission Mounting
    GC0005195Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - ENGINE TO TRANSMISSION COLLAR
    3 - TRANSMISSION
  29. Align and connect propeller shaft(s).
  30. Adjust gearshift cable if necessary.
  31. Install any skid plates removed previously. See Fig 10. (Refer to FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLATION)
    Fig 10: Install Skid Plate
    GC0009447Courtesy of DAIMLERCHRYSLER CORP.
    1 - SKID PLATE
    2 - TRANSMISSION CROSSMEMBER
    3 - FRAME RAILS
  32. Lower vehicle.
  33. Fill transmission with Mopar® ATF +4, type 9602, Automatic Transmission Fluid.
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