Dodge Durango

 Service Manual

Transmission and Transfer Case » Removal and installation
Transmission

The overdrive unit can be removed and serviced separately. It is not necessary to remove the entire transmission assembly to perform overdrive unit repairs.

CAUTION: The transmission and torque converter must be removed as an assembly to avoid component damage. The converter drive plate, pump bushing, or oil seal can be damaged if the converter is left attached to the driveplate during removal.

REMOVAL

(1) Disconnect battery negative cable.

(2) Hoist and support vehicle.

(3) Remove skid plate, if equipped.

(4) Remove skid plate support crossmember, if equipped.

(5) Disconnect and lower or remove necessary exhaust components.

(6) Remove starter motor.

(7) Support engine with suitable support stand and wood block.

(8) Remove bolts attaching engine-to-transmission brackets to transmission.

(9) Remove bolt and nut attaching each engine-totransmission bracket to the motor mounts.

(10) Remove bolts holding the engine-to-transmission brackets to the front axle, if equipped.

(11) Loosen bolts attaching engine-to-transmission brackets to each side of the engine block.

(12) Raise engine slightly.

(13) Remove torque converter access cover.

(14) Tighten bolts attaching engine-to-transmission brackets to each side of the engine block.

(15) Lower engine.

(16) Disconnect fluid cooler lines at transmission.

(17) If transmission is being removed for overhaul, remove transmission oil pan, drain fluid and reinstall pan.

(18) Remove fill tube bracket bolts and pull tube out of transmission. Retain fill tube seal. On 4 x 4 models, it will also be necessary to remove bolt attaching transfer case vent tube to converter housing (Fig. 73).

Fig. 73 Fill Tube Attachment

1 - TRANSFER CASE VENT TUBE

2 - FILL TUBE (V8)

3 - TUBE SEAL

4 - FILL TUBE (V6)

(19) Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.

(20) Mark propeller shaft and axle companion flanges for assembly alignment. Then disconnect and remove propeller shaft.

(21) Disconnect wires from park/neutral position switch and transmission solenoid.

(22) Disconnect throttle valve cable from transmission bracket and throttle valve lever.

(23) On 4 x 4 models, disconnect shift rod from transfer case shift lever. Or remove shift lever from transfer case and tie rod and lever to chassis component with wire.

(24) Raise transmission slightly with service jack to relieve load on crossmember and supports.

(25) Remove bolts securing rear support and cushion to transmission and crossmember. Raise transmission slightly, slide exhaust hanger arm from bracket (Fig. 74) and remove rear support.

(26) Remove bolts attaching crossmember to frame and remove crossmember.

(27) On 4 x 4 models, disconnect vent hose from transfer case. Then remove transfer case with transmission jack or aid of helper.

(28) Remove all converter housing bolts.

(29) Carefully work transmission and torque converter assembly rearward off engine block dowels.

(30) Lower transmission and remove assembly from under the vehicle.

Fig. 74 Rear Support Cushion

1 - EXHAUST PIPE ARM AND BRACKET

2 - CROSSMEMBER

3 - REAR SUPPORT AND CUSHION

INSTALLATION

(1) Check torque converter hub and hub drive notches for sharp edges burrs, scratches, or nicks.

Polish the hub and notches with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation.

(2) Lubricate oil pump seal lip with transmission fluid.

(3) Lubricate converter pilot hub pocket in the rear of the crankshaft with a light coating of Mopart High Temp Grease.

(4) Align and install converter in 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 (Fig. 75). Surface of converter lugs should be 1/2 in. to rear of straightedge when converter is fully seated.

(7) Temporarily secure converter with wedge tool or C-clamp.

(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 held transmission in alignment.

(10) Raise transmission and align converter with drive plate and converter housing with engine block.

(11) Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.

Fig. 75 Typical Method Of Checking Converter Seating

1 - SCALE

2 - STRAIGHTEDGE

(12) Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.

(13) Install bolts attaching converter housing to engine.

(14) Install rear support. Then lower transmission onto crossmember and install bolts attaching transmission mount to crossmember.

(15) Install new plastic retainer grommet on any shift linkage rod or lever that was disconnected.

Grommets should not be reused.

(16) Connect gearshift and throttle cable to transmission.

(17) Connect wires to park/neutral position switch, transmission solenoid(s) and oxygen sensor. Be sure transmission harnesses are properly routed.

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.

(18) Install torque converter-to-driveplate bolts.

Tighten bolts to 31 N*m (270 in. lbs.).

(19) Raise engine slightly.

(20) Loosen bolts attaching engine-to-transmission brackets to each side of the engine block.

(21) Install converter housing access cover.

(22) Install bolts attaching engine-to-transmission brackets to transmission.

(23) Tighten bolts attaching engine-to-transmission brackets to each side of the engine block.

(24) Lower engine.

(25) Install bolt and nut attaching each engine-totransmission bracket to the motor mounts.

(26) Remove engine support.

(27) Install bolts to hold engine-to-transmission brackets to the front axle, if equipped.

(28) Install starter motor and cooler line bracket.

(29) Connect cooler lines to transmission.

(30) Install transmission fill tube. Install new seal on tube before installation.

(31) Install exhaust components.

(32) Install transfer case, if necessary.

(33) Align and connect propeller shaft(s).

(34) Install rear skid plate, if equipped.

(35) Adjust gearshift linkage and throttle valve cable if necessary.

(36) Install front skid plate, if equipped.

(37) Lower vehicle.

(38) Fill transmission with Mopart ATF Plus 3, Type 7176 fluid.

Transmission

Torque converter

Yoke seal replacement

Park/neutral position switch

Gearshift cable

Governor solenoid and pressure sensor

Valve body

Overdrive unit

Overdrive housing bushing

Output shaft rear bearing

Output shaft front bearing