Installation
Transmission - Diesel EnginesSpecial Tool(s):
Material:
All vehicles
1. Using the transmission jack, raise and position the transmission to the engine and clutch.
2. Install the six transmission-to-engine bolts.
3. Position the crossmember in the vehicle. Install the LH crossmember bolts.
4. Install the RH crossmember nuts.
5. Install the transmission mount nuts.
6. Attach the wire harness to the crossmember.
7. Remove the transmission jack.
8. Connect the transmission cooler tubes.
9. Install the clutch slave cylinder.
^ Rotate the clutch slave cylinder clockwise 45° to lock in position.
10. Install the transfer case, if equipped.
^ If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned.
11. NOTE: Make sure the index marks made during removal are aligned.
NOTE: Install new bolts.
Connect the driveshaft.
12. Install any power take-off (PTO) equipment, if equipped.
13. Connect the reverse lamp switch electrical connector.
14. Connect the wiring harness to the transmission.
15. Refill the transmission to specification.
^ Refill the transmission with clean transmission fluid.
16. Lower the vehicle.
17. CAUTION: Do not use a silicone sealing compound.
NOTE: Do not wait longer than ten minutes to tighten the four bolts due to the rapid cure time of the sealant.
Install the gearshift lever and shift housing assembly.
^ Apply gasket maker to the shift housing and the main case.
18. Install the four shift lever boot screws.
Vehicles with a manual shift transfer case
19. Position the shift lever with the bezel and boot assembly. Install the shift lever bolt.
20. Position the bezel and boot assembly and install the screws.
21. Verify the shift sequence from 2H to 4L to 2H.