Manual Trans Fluid Change

Drain and refill the manual transmission with fresh Pennzoil Synchromesh 75W-90 fluid to maintain proper lubrication and shifting performance.

Warnings

Tools required

Parts

• Drain plug crush washer × 1 — Mopar 6504596 or equivalent aluminum washer
• Fill plug O-ring × 1 — Mopar 68003912AA or equivalent

Fluids

• Pennzoil Synchromesh 75W-90 — 4.2 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. If recently driven, allow transmission to cool for at least 30 minutes.
3. Raise vehicle using hydraulic jack at factory lift points and secure on jack stands rated for vehicle weight (approximately 3,400 lbs).
4. Ensure vehicle is stable and level to allow complete fluid drainage and accurate fill level.
5. Locate the transmission drain plug on the bottom of the transmission case and the fill plug on the driver's side of the transmission case.

Procedure

1. 1

   Position drain pan and remove drain plug
   Position the drain pan directly under the transmission drain plug located at the bottom rear of the transmission case. Using the correct hex/square drive tool for the plug (verify size against factory spec — many T56 plugs use a 3/8" square drive or large Allen), loosen and remove the drain plug. Allow fluid to drain completely into the pan. This will take several minutes; verify exact fill capacity against the factory service manual before refilling.
2. 2

   Inspect and clean drain plug
   Once fluid has fully drained, inspect the drain plug threads and magnetic tip for metal debris. Small amounts of fine metal particles are normal, but large chunks or excessive material may indicate internal transmission wear. Clean the plug threads and magnetic tip thoroughly with a shop towel. Remove and discard the old aluminum crush washer from the drain plug.
3. 3

   Install new crush washer and reinstall drain plug
   Install the new aluminum crush washer onto the drain plug. Thread the drain plug into the transmission case by hand to avoid cross-threading. Torque the drain plug to the factory-specified value (verify in service manual — do not rely on unconfirmed 20 ft-lbs) using a torque wrench.
4. 4

   Remove fill plug
   Locate the fill plug on the side of the transmission case (verify exact side and height against factory spec). Using the correct hex/square drive tool for the plug, loosen and remove the fill plug. Inspect the fill plug O-ring for damage or hardening and replace if necessary.
5. 5

   Fill transmission with fresh fluid
   Using a fluid pump with hose inserted into the fill hole, pump the factory-specified quantity of the correct Chrysler-specified manual transmission fluid into the transmission (verify fluid type and capacity against the service manual before filling). Pump slowly to allow air to escape and fluid to settle. Fluid is at the correct level when it begins to seep out of the fill hole. The fill hole is positioned at the proper fluid level height.
6. 6

   Reinstall fill plug
   Install the new O-ring onto the fill plug if replacing. Wipe away any excess fluid from the transmission case around the fill hole. Thread the fill plug into the case by hand, then torque to the factory-specified value (verify in service manual — do not rely on unconfirmed 20 ft-lbs) using a torque wrench.
7. 7

   Lower vehicle and dispose of fluid
   Remove jack stands and carefully lower the vehicle to the ground. Dispose of the used transmission fluid at an appropriate recycling facility or automotive service center. Do not pour fluid down drains or onto the ground.

Reassembly

1. No disassembly was required for this procedure.

Verification

• Start the engine and allow it to idle for 1 minute, then shut off.
• Check the area around both drain and fill plugs for any signs of leakage.
• Test drive the vehicle through all gears to verify smooth shifting operation.
• After test drive, re-inspect drain and fill plugs for leaks while transmission is at operating temperature.
• Verify no fluid drips or puddles appear under the transmission after the vehicle has been parked.

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