Jeep XJ. Manual — part 468
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page
page
NV3550 MANUAL TRANSMISSION . . . . . . . . . . . . 1
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 5
NV3550 MANUAL TRANSMISSION
TABLE OF CONTENTS
page
page
REMOVAL AND INSTALLATION
TRANSMISSION - 2.5L TURBO DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
TRANSMISSION - 2.5L TURBO DIESEL ENGINE
REMOVAL
1. Disconnect and isolate the negative battery
cable.
2. Remove the floor console, shifter boot and
shifter. Refer to group 23, Body for the procedure.
3. Raise the vehicle on a hoist.
4. Drain the transmission fluid (Fig. 1).
5. Remove exhaust pipe and heat shield.
6. Mark the front and rear propeller shafts for
installation alignment (Fig. 2).
7. Remove the front propeller shaft.
8. Remove the rear propeller shaft.
9. Remove the transmission skid plate.
10. Disconnect the transfer case linkage and vehi-
cle speed sensor electrical connector and vent tube
hose (Fig. 3).
11. Support the engine with an adjustable jack
stand.
12. Place a transmission jack under the transmis-
sion and secure the transmission with safety chains.
Fig. 1 Drain Plug and Backup Light Switch Location
1 – GEAR CASE
2 – BACKUP LIGHT SWITCH
3 – DRAIN PLUG
Fig. 2 Marking Propeller Shaft and Axle Yoke
1 – MARK BOTH YOKES FOR ALIGNMENT AT INSTALLATION
XJ
TRANSMISSION AND TRANSFER CASE
21 - 1
2000 JEEP CHEROKEE
13. Remove the rear transmission mount.
14. Remove the rear crossmember.
15. Remove the transfer case assembly. Refer to
Transfer Case removal later in this Group.
16. Lower the engine and transmission no more
than 7.6 cm.
17. Remove the two (2) upper and two (2) mid
clutch housing to engine bolts.
18. Remove the engine speed sensor (crankshaft
position sensor) (Fig. 4).
19. Remove the clutch slave cylinder from the
clutch housing.
20. Remove the lower transmission bolts.
21. Remove the transmission assembly from the
vehicle.
INSTALLATION
1. Mount the transmission on a transmission jack
and secure the transmission with safety chains.
2. Position the transmission in the vehicle (Fig. 5).
3. Install the two (2) lower transmission bolts.
Tighten the bolts to 74.6 N·m.
4. Install the clutch slave cylinder on the clutch
housing.
5. Install the engine speed sensor (crankshaft posi-
tion sensor) on the vehicle (Fig. 4).
6. Install the two (2) upper clutch housing to
engine bolts. Tighten the bolts to 36.6 N·m.
7. Install the two (2) mid clutch housing to engine
bolts. Tighten the bolts to 58.3 N·m.
8. Raise the engine and transmission with the
adjustable jackstand.
9. Install the transfer case assembly. Refer to
Transfer Case installation later in this Group.
10. Install the rear crossmember.
11. Install the rear transmission mount.
12. Connect the transfer case linkage and vehicle
speed sensor electrical connector and vent tube (Fig.
3).
13. Install the transmission skid plate.
14. Install the front and rear propeller shafts in
there original position, using the reference marks
scribed earlier.
15. Install the exhaust pipe and heat shield.
16. Remove the transmission jack.
17. Fill the transmission with the proper fluid
(Fig. 7).
18. Remove the adjustable jackstand from under
the engine.
19. Lower the vehicle from the hoist.
20. Install the shifter, shifter boot and floor con-
sole.
21. Reconnect the negative battery cable.
22. Using the DRB III Scan Tool clear any DTC’s
and reset customer preferences.
Fig. 3 Vehicle Speed Sensor
1 – SENSOR ELECTRICAL CONNECTOR
2 – 4WD TRANSFER CASE EXTENSION
3 – VEHICLE SPEED SENSOR
Fig. 4 Engine Speed Sensor
1 – ENGINE SPEED SENSOR
2 – GROMMET
3 – MOUNTING BOLT(S)
4 – LEFT REAR OF ENGINE
5 – TRANSMISSION
21 - 2
TRANSMISSION AND TRANSFER CASE
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
Fig. 5 Transmission to Engine Mounting
1 – ENGINE BLOCK
2 – FLYWHEEL
3 – CLUTCH HOUSING AND TRANSMISSION
4 – CLUTCH COVER
5 – CLUTCH DISC
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TRANSMISSION AND TRANSFER CASE
21 - 3
SPECIFICATIONS (Continued)
2000 JEEP CHEROKEE
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