Replace the transmission output shaft bearing by removing the transmission, disassembling the rear extension housing, and installing a new bearing with proper sealing and reassembly.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification
• Transmission extension housing gasket × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• Mopar ATF+4 — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect both battery cables, negative first
3. Raise vehicle on lift or place on heavy-duty jack stands at manufacturer-specified lift points
4. Remove skid plates and transmission access covers if equipped
5. Place large drain pans under transmission and transfer case
6. Mark driveshaft-to-flange orientation with paint or marker for proper reassembly phasing
7. Photograph or diagram all electrical connections and mounting points
8. Support engine with support bar or chain hoist to prevent tipping when transmission is removed

Procedure

1. 1

   Drain transmission and transfer case fluids
   Remove the transmission drain plug using appropriate socket and drain fluid completely into drain pan. Remove transfer case drain plug and drain fluid. Remove transmission pan bolts in criss-cross pattern and lower pan to drain remaining fluid. Clean pan and inspect for metal particles indicating bearing failure. Remove and discard old gasket material.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)

   Pan Bolts22 Nm (16 lb-ft)
2. 2

   Disconnect driveshafts and remove
   Remove front driveshaft by unbolting from transfer case and front differential. Remove rear driveshaft by unbolting at rear differential and transfer case output. Support driveshafts while removing to prevent damage to universal joints. Cap or plug all openings to prevent fluid loss and contamination.
3. 3

   Disconnect electrical and mechanical connections
   Disconnect transmission electrical connector, speed sensors, and shift linkage. Remove all sensor bolts as needed. Disconnect transmission cooler lines at transmission (have drain pan ready for fluid). Disconnect exhaust system at appropriate hangers to allow clearance for transmission removal. Remove starter motor mounting bolts and secure starter out of the way.
   Torque spec

   Sensor Bolts15 Nm (11 lb-ft)
4. 4

   Remove transfer case from transmission
   Support transfer case with transmission jack. Remove transfer case mounting bolts securing it to transmission adapter. Carefully slide transfer case rearward off transmission output shaft. Lower transfer case and set aside. Remove transfer case adapter from transmission if necessary for access.
5. 5

   Support and remove transmission
   Position transmission jack under transmission and secure with safety chains. Remove transmission crossmember mounting bolts and lower crossmember. Remove transmission mounting bolts securing transmission to engine bellhousing. Verify all connections are disconnected. Carefully slide transmission rearward off engine dowel pins and input shaft from clutch or torque converter. Lower transmission gradually while maintaining balance.
   Torque spec

   Mounting Bolts82 Nm (61 lb-ft)
6. 6

   Remove extension housing from transmission
   Place transmission on clean workbench with output shaft facing up. Remove all extension housing bolts or cover screws. Note location of any different length bolts. Use soft mallet to tap extension housing loose if necessary. Carefully pull extension housing straight back off output shaft to avoid damaging components. Remove and discard housing gasket.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
7. 7

   Remove output shaft assembly
   Remove snap ring retaining output shaft if equipped. Note position and orientation of all components. Carefully slide output shaft assembly forward and out of transmission case. Place on clean work surface. Inspect output shaft for scoring, wear, or damage. If shaft is damaged, it must be replaced as bearing failure may have caused secondary damage.
   ⚠Keep all components in order and note orientation. Output shaft components must be reassembled in exact sequence.
8. 8

   Remove failed bearing from output shaft
   Support output shaft in padded vise or on press bed. Use bearing puller to remove failed bearing from shaft. If bearing inner race is seized, use appropriate bearing splitter and press to remove. Inspect bearing bore on shaft for scoring or damage. Clean shaft thoroughly with solvent and inspect for cracks using magnification. Measure shaft diameter at bearing surface to ensure within specification.
   ⚠Do not damage output shaft surface during bearing removal. Any scratches or gouges will cause premature failure of new bearing.
9. 9

   Remove bearing race from extension housing
   Inspect extension housing for bearing outer race. Use bearing race puller or driver to remove outer race from housing bore. Clean housing bore thoroughly. Inspect bore for damage, scoring, or out-of-round condition. If housing bore is damaged, housing must be replaced.
10. 10

    Install new bearing race in extension housing
    Place new bearing outer race in freezer for 30 minutes before installation (optional but recommended). Clean housing bore with lint-free cloth. Using appropriate bearing race driver, press new outer race squarely into housing bore until fully seated. Verify race is fully seated and flush with housing shoulder. Apply light coating of ATF+4 to race surface.
11. 11

    Install new bearing on output shaft
    Place new bearing in warm ATF+4 (120°F maximum) for 10-15 minutes to expand slightly. Support output shaft vertically in press or on clean surface. Using appropriate bearing driver that contacts inner race only, press bearing onto shaft until it seats against shoulder or snap ring groove is visible. Install snap ring if equipped. Verify bearing rotates smoothly without binding. Apply light coating of ATF+4 to bearing.
    ⚠️Never press on bearing outer race or rollers. Press only on inner race to avoid bearing damage.
12. 12

    Install new output shaft seal
    Remove old output shaft seal from extension housing using seal puller or screwdriver. Clean seal bore in housing. Lightly lubricate new seal lip with ATF+4. Using appropriate seal driver, press new seal squarely into housing bore until flush with housing surface. Verify seal is not cocked or damaged.
13. 13

    Reassemble transmission output shaft assembly
    Install output shaft assembly back into transmission case, ensuring all components are in correct sequence and orientation as noted during disassembly. Install snap ring if equipped and verify proper seating. Install new extension housing gasket on transmission case. Apply small amount of thread locker to extension housing bolt threads. Align extension housing and carefully slide onto output shaft and over bearing. Install and tighten housing bolts or cover screws in criss-cross pattern to proper torque specification.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
14. 14

    Reinstall transmission in vehicle
    Position transmission on transmission jack and raise into position. Align transmission with engine and carefully slide forward onto dowel pins, engaging input shaft with clutch or torque converter. Install transmission mounting bolts and tighten to specification. Install crossmember and tighten mounting bolts to specification. Reconnect all electrical connectors, sensors, shift linkage, and cooler lines. Reinstall starter motor.
    Torque spec

    Mounting Bolts82 Nm (61 lb-ft)
15. 15

    Install transfer case and driveshafts
    Install transfer case adapter if removed. Position transfer case on jack and raise to transmission. Align transfer case with transmission output shaft and slide forward. Install transfer case mounting bolts and tighten to specification. Install front and rear driveshafts, aligning marks made during disassembly to maintain proper phasing. Tighten all driveshaft bolts to specification. Reconnect exhaust system.
16. 16

    Refill fluids and perform final checks
    Install new transmission drain plug crush washer and install drain plug, torquing to specification. Install transmission pan with new gasket and tighten pan bolts in criss-cross pattern to specification. Fill transmission with 10 quarts of Mopar ATF+4 through fill tube. Fill transfer case with 2.5 quarts of Mopar Transfer Case Fluid. Reconnect battery cables, positive first. Install skid plates and access covers.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

    Pan Bolts22 Nm (16 lb-ft)

Reassembly

1. Ensure all mounting bolts are torqued to specification using proper tightening sequence
2. Verify all electrical connectors are fully seated and locked
3. Check that all driveshaft U-bolts or flange bolts are tight and properly phased
4. Confirm no tools or parts have been left in or around transmission area
5. Double-check that transmission and transfer case are filled to proper level

Verification

• Start engine and verify no leaks from transmission, extension housing, or transfer case
• With engine running and transmission in Park, check fluid level on dipstick and add as needed to bring to proper level on hot range after warmup
• Road test vehicle through all gears and verify smooth shifting with no unusual noises from transmission or driveline
• Check for vibration at highway speeds that could indicate driveshaft phasing issue
• Recheck all fluid levels after road test and inspect for leaks
• Verify output shaft bearing noise is eliminated
• Recheck torque on all critical fasteners after 50-100 miles of operation

More procedures for this vehicle