Operation CHARM: Car repair manuals for everyone.

Removal

REMOVAL
1. Disconnect battery negative cable.
2. Shift transmission into Neutral.
3. Remove shift boot bezel screws and slide boot upward on shift lever extension.
4. Remove shift lever extension from the shift tower and lever assembly.
5. Remove bolts attaching shift tower and lever assembly to rear case. Then remove shift tower and lever assembly.
6. Raise vehicle on hoist.
7. Remove crankshaft position sensor. Retain sensor attaching bolts.
8. Remove skid plate, if equipped.
9. Drain transmission lubricant if transmission will be disassembled for service.
10. Mark propeller shaft/shafts and yoke/yokes for installation reference and remove propeller shaft/ shafts.
11. Disengage harness from clips on transmission housing.
12. Support engine with adjustable jack stand and wood block.
13. Drain transmission lubricant if transmission will be disassembled for service.

TWO WHEEL DRIVE





1. Remove nuts attaching rear mount to crossmember (Fig. 2). Then remove insulator from extension housing if necessary.
2. Remove bolts and nuts attaching crossmember to frame rails. Rotate crossmember diagonally and remove crossmember.
3. Disconnect exhaust as necessary.
4. Remove slave cylinder attaching nuts and remove cylinder from clutch housing.
5. Remove starter motor.
6. Support and secure transmission with safety chains to a transmission jack.
7. Remove nuts/bolts attaching transmission front housing to engine.
8. Remove transmission dust shield.
9. Move transmission rearward until input shaft is clear of clutch disc and cover. Then lower jack and remove transmission from under vehicle.

FOUR WHEEL DRIVE
1. Disconnect transfer case shift linkage at transfer case range lever.
2. Remove bolts attaching shift linkage bracket to transfer case and move linkage and bracket aside.
3. Support transfer case with transmission jack.
4. Remove nuts attaching transfer case to transmission adapter housing.
5. Remove transfer case with aid of helper.
6. Support engine with a jack stand and a wood block.
7. Remove nuts and bolts attaching support bracket and cushions to fixed crossmember.
8. Remove nuts and bolts attaching removable crossmember to frame rails.
9. Remove crossmember.
10. Disconnect exhaust as necessary.
11. Remove slave cylinder attaching nuts and remove cylinder from clutch housing. Move cylinder aside for working clearance.
12. Remove clutch housing dust cover.
13. On some models, it may be necessary to remove front axle struts and oil filter for access and removal clearance. Remove these components if necessary.
14. Support transmission with transmission jack. Secure transmission to jack with safety chains.
15. Remove bolts attaching transmission clutch housing to engine block.
16. Move transmission rearward until transmission input shaft is clear of clutch disc and cover. Then lower jack and remove transmission from under vehicle.