Manual Transmission Removal and Installation

REMOVAL

WARNING: Make sure lifts are placed properly, and hoist brackets are attached to correct positions.





1. Check and record the rear wheel alignment.
2. Disconnect the battery negative H and positive cables from the battery.
3. Drain transmission oil. Reinstall the drain plug with a new washer.
4. Remove the strut bar.
5. Remove the air cleaner assembly.
6. Remove the connectors from the control box, and remove the control box. Do not remove the vacuum tubes from the control box.
7. Remove the wire harness holder, jumper connector and transmission ground cable.
8. Disconnect the back-up light switch, neutral position switch, differential speed sensor, reverse lockout solenoid, and Vehicle Speed Sensor (VSS) connectors.
9. Disconnect the starter motor cables, then remove the starter motor.
10. Remove the transmission mount.
11. Remove the two transmission housing bolts.





12. Remove the parking brake cable holders from the rear beam rod.
13. Remove the rear beam rod.





14. Remove the parking brake cable holder from the rear sub frame, and the wheel sensor wire clamp from the lower control arm.
15. Remove the flange bolt, and separate the toe control arm from the side beam.
16. Remove the damper fork bolt.
17. Remove the adjusting bolt and the flange bolt, then separate the lower control arm from the side beam.
18. Pry the driveshaft out of the differential. Pull and remove it.





19. Remove the intermediate shaft heat cover and the intermediate shaft mounting bolts.
20. Pry the intermediate shaft out of the differential. Pull and remove it. Coat all precision finished surfaces with clean engine oil or grease. Tie plastic bags over the driveshaft ends.





21. Remove the parking brake cable holder from the rear sub frame, and the wheel sensor wire clamp from the lower control arm.
22. Remove the flange bolt, and separate the toe control arm from the side beam.
23. Remove the damper fork bolt.
24. Remove the adjusting bolts, and the flange bolt, then separate the lower control arm from the side beam.
25. Pry the driveshaft out of the differential. Pull and remove it. Coat all precision finished surfaces with clean engine oil or grease. Tie plastic bags over the driveshaft ends.
26. Remove the one of the upper control arm mounting bolt.
27. Remove the lower cover, change wire bracket and upper cover.
28. Remove the shift cable and select cable.
29. Remove the slave cylinder from the transmission. Do not operate the clutch pedal once the slave cylinder has been removed.





30. Remove the release fork from the clutch release hanger, then hang the release fork on the clutch housing.





31. Remove the clutch housing cover.
32. Attach a chain hoist to the transmission hangers.
33. Place a jack under the transmission, and raise the transmission just enough to take weight off mounts.
34. Remove the front engine mounting bolts on the transmission side, and retighten the bolt on the engine side. Loosen the front engine mounting bolt on the engine side, but do not remove it. After removing the two bolts on the transmission side, be sure to retighten the bolt on the engine side.
35. Remove the rear transmission mounting bolts and engine stiffener.
36. Remove the transmission housing mounting bolts.
37. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmission jack.

INSTALLATION

NOTE: Use only Super High Temp Urea Grease (P/N 08798-9002).





1. Place the transmission on the transmission jack, and raise it to the engine level. Check that the two dowel pins are installed in the clutch housing.
2. Set the release fork to the clutch housing.
3. Install the two transmission housing mounting bolts and engine stiffener.
4. Install the three rear transmission mounting bolts.
5. Loosen the front engine mounting bolt, then install the two front engine mounting bolts to the transmission side.
6. Remove the transmission jack.
7. Install the clutch housing cover.





8. Install the release fork in the release hanger, then install the slave cylinder.
9. Connect the shift cable and select cable. Take care not to bend the cables.
10. Install the upper cover, change wire bracket and lower cover.
11. Install the upper control arm mounting bolt.





12. Install a new set ring on the end of the left driveshaft and intermediate shaft.
13. Install the left driveshaft.
14. Install the lower control arm to the side beam. Align the reference marks on the adjusting bolt, adjusting cam and lower control arm.
15. Install the damper fork bolt.
16. Install the toe control arm to the side beam. Make sure that the arrow marks on the toe control arm are aligned.
17. Install the wheel sensor wire clamp and parking brake cable holder.
18. Install the intermediate shaft, and tighten the intermediate shaft mounting bolts to the intermediate shaft support base.





19. Install the intermediate shaft heat cover.





20. Install the right driveshaft onto the intermediate shaft.
21. Install the lower control arm to the side beam. Align the reference marks on the adjusting bolt, adjusting cam and lower control arm.
22. Install the damper fork bolt.
23. Install the toe control arm to the side beam. Make sure that the arrow marks on the toe control arm are aligned.
24. Install the wheel sensor wire clamp and parking brake cable holder.





25. Install the rear beam rod.
26. Install the parking brake cable holders on the rear beam rod.





27. Install the transmission mount and two transmission housing mounting bolts.
28. Install the starter motor, and connect the starter motor cables. Make sure that the crimped side of the ring terminals facing out.
29. Install the transmission ground cable and jumper connector, and connect the back-up light switch, neutral position switch, differential speed sensor, reverse lockout solenoid, and Vehicle Speed Sensor (VSS) connector.
30. Install the control box, and connect the control box connectors.
31. Install the air cleaner assembly.
32. Install the strut bar.
33. Refill the transmission with the recommended oil.
34. Connect the battery positive (+) and negative cables to the battery.
35. Inspect the rear camber.
36. Check the clutch operation.
37. Shift the transmission, and check for smooth operation.