G56 Manual Transmission - Removal

REMOVAL


1. With vehicle in neutral, position vehicle on hoist.
2. Disconnect battery negative cable.
3. Remove shift boot bezel and slide boot upward on shift lever extension.







4. Remove inner boot (1) from floor pan and remove shift tower (2) from transmission (3).
5. Remove 4WD shift boot if equipped.
6. Remove skid plate, if equipped.







7. Remove drain plug (1) from transmission (2) and drain fluid.







8. Mark transmission flange (1) and propeller shaft (2) for installation reference before removing propeller shaft. If 4x4 equipped mark transfer case and front propeller shaft before removing shaft.
9. Disconnect harness from clips on transmission housing.
10. Remove transfer case linkage 4x4 equipped.
11. Remove transfer case mounting nuts and remove transfer case 4x4 equipped.







CAUTION: Do not allow release lever plunger to pivot more than 20 in either direction in the slave cylinder bore. Allowing the plunger to pivot more than 20 in the bore will cause fluid to bypass the seal and result in fluid leakage.

12. Remove slave cylinder (1) mounting nuts (2) and remove cylinder by pulling straight back.







13. Remove starter motor (1) on 5.7L engine.







14. Remove structural dust cover (1) clutch housing bolts (2) and dust shield bolts (3) on 5.7L engine.

CAUTION: On 5.7L engine do not remove structural dust cover from engine block. If cover is removed clutch housing and structural dust cover must be aligned with the engine.







15. Remove exhaust bracket (1) bolts and remove bracket on diesel engine.







16. Support engine with adjustable jack stand and wood block.
17. Support and secure transmission (1) to a transmission jack (2) with safety chains.







18. Remove transmission mount nuts (1) from crossmember (2).







19. Remove rear crossmember bolts (2) and remove crossmember with transmission mount.
20. Remove exhaust pipe on 5.7L engine.
21. Remove bolts attaching transmission to the engine.
22. Move transmission rearward until input shaft is clear of clutch disc and pressure plate. Then lower jack and remove transmission from under vehicle.