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Servicing - A/t: Removal & Installation Dodge Durango II

Automatic Trans 18 illustrations ~1026 words

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Removal

  1. Shift transmission into "PARK".
  2. Raise vehicle.
  3. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket. (Scheme 1)
  4. Lower the vehicle.
  5. Remove the dash panel insulation pad as necessary to access to the gearshift cable grommet. (Scheme 2)
  6. Remove grommet from the dash panel.
  7. Remove any steering column trim necessary to access to the gearshift cable and BTSI mechanism.
  8. Disconnect the BTSI wiring connector.
  9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. (Scheme 3)
  10. Remove gearshift cable from vehicle.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Installation

  1. Route the transmission end of the gearshift cable through the opening in the dash panel. (Scheme 2)
  2. Seat the cable grommet into the dash panel opening.
  3. Snap the cable into the steering column bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. (Scheme 3)
  4. Raise the vehicle.
  5. Place the transmission manual shift lever in the "PARK" detent position and rotate prop shaft to ensure transmission is in "PARK".
  6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable, retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud.
  7. Lower vehicle.
  8. Lock the shift cable adjustment by pressing the cable adjuster lock tab downward until it snaps into place.
  9. Check for proper operation of the transmission range sensor.
  10. Adjust the gearshift cable and BTSI mechanism as necessary. See «ADJUSTMENTS»(ref-170067-S06996317382005010300000).
  1. Raise vehicle.
  2. Place a suitable fluid catch pan under the transmission.
  3. Remove the wiring connector from the input speed sensor. (Scheme 4)
  4. Remove the bolt holding the input speed sensor to the transmission case.
  5. Remove the input speed sensor from the transmission case.

Scheme 4

Scheme 4
Scheme 4
  1. Install the input speed sensor into the transmission case.
  2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 105 INCH Lbs. (12 N.m).
  3. Install the wiring connector onto the input speed sensor.
  4. Verify the transmission fluid level. Add fluid as necessary. See «CHECKING FLUID LEVEL»(ref-170067-S17426121062005010300000) under LUBRICATION.
  5. Lower vehicle.
  1. Raise vehicle.
  2. Place a suitable fluid catch pan under the transmission.
  3. Remove the wiring connector from the output speed sensor. (Scheme 5)
  4. Remove the bolt holding the output speed sensor to the transmission case.
  5. Remove the output speed sensor from the transmission case.

Scheme 5

Scheme 5
Scheme 5
  1. Install the output speed sensor into the transmission case.
  2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 105 INCH Lbs. (12 N.m).
  3. Install the wiring connector onto the output speed sensor.
  4. Verify the transmission fluid level. Add fluid as necessary. See «CHECKING FLUID LEVEL»(ref-170067-S17426121062005010300000) under LUBRICATION.
  5. Lower vehicle.
  1. Remove valve body assembly from vehicle.
  2. Remove the manual shaft seal. (Scheme 6)
  3. Remove manual shaft/TRS retaining screw. (Scheme 7)
  4. Slide TRS off of manual valve shaft.

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. Install the TRS to the manual shaft. Install the manual shaft seal.
  2. Make sure TRS locating pin rests in manual valve bore slot.
  3. Install the TRS/manual shaft retaining screw and torque to 45 INCH Lbs. (5 N.m).
  4. Install valve body to the transmission.

Removal (545RFE)

  1. Shift transmission into "PARK".
  2. Raise vehicle.
  3. Disconnect wires at the solenoid and pressure switch assembly connector.
  4. Position drain pan under transmission oil pan.
  5. Remove transmission oil pan.
  6. Remove the primary oil filter from valve body. (Scheme 8)
  7. Remove bolts attaching valve body to transmission case. (Scheme 9)
  8. Lower the valve body and work the electrical connector out of transmission case.
  9. Separate the valve body from the transmission.

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Installation (545RFE)

  1. Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn.
  2. Place TRS selector plate in the PARK position.
  3. Place the transmission in the PARK position.
  4. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly.
  5. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever.
  6. Seat valve body in case and install one or two bolts to hold valve body in place.
  7. Tighten valve body bolts alternately and evenly to 105 INCH Lbs. (12 N.m).
  8. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool.
  9. Place replacement filter in position on valve body and into the oil pump.
  10. Install screw to hold filter to valve body. Tighten screw to 35 INCH Lbs. (4 N.m).
  11. Connect the solenoid and pressure switch assembly connector.
  12. Install oil pan. Tighten pan bolts to 105 INCH Lbs. (12 N.m).
  13. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602, fluid.
  14. Check and adjust gearshift cable, if necessary. See «ADJUSTMENTS»(ref-170067-S06996317382005010300000) .

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Removal (42RLE)

  1. Disconnect the TRS and solenoid wiring connectors.
  2. Disconnect the shift cable from the shift lever (at the transmission).
  3. Move the manual shift lever clockwise as far as it will go. This should be one position past the L position. Then remove the manual shift lever.
  4. Remove transmission pan bolts. (Scheme 13)
  5. Remove transmission oil pan. (Scheme 14)
  6. Remove oil filter from valve body. It is held in place by two screws. (Scheme 15)
  7. Remove valve body bolts-to-case. (Scheme 16)
  8. Carefully remove valve body assembly from the transmission. (Scheme 17)

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Installation (42RLE)

  1. Install valve body into position and start bolts. Torque valve body to transmission case bolts to 105 INCH Lbs. (12 N.m). (Scheme 16)
  2. Install transmission oil filter. (Scheme 15)
  3. Make sure oil pan and case rail are clean and dry. Install an 1/8" bead of RTV to the transmission oil pan and install to case. Tighten bolts to 14.5 ft. lbs. (20 N.m). (Scheme 13)
  4. Lower vehicle and connect the TRS connector.
  5. Connect solenoid/pressure switch assembly connector.
  6. Lower vehicle.
  7. Fill transmission with ATF+4, Automatic Transmission Fluid. Verify proper fluid level. See «FLUID CAPACITIES»(ref-170067-S10300773082005010300000).

Scheme 18

Scheme 18
Scheme 18

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