Owner Notification and Service Procedure
OWNER NOTIFICATION
There will be no owner letter sent out with this campaign. Due to the stop sale issued prior to vehicle sale, it is anticipated the vehicles should still be in your new vehicle inventory and should be repaired prior to retail sale. If a unit has been retailed, in order to maintain customer satisfaction, contact the owner immediately and arrange to correct this condition on his/her vehicle.
SERVICE PROCEDURE
Remove Tool Required:
J 21366 Convertor Holding Strap
1. Negative (-) battery cable.
2. TV cable from the throttle linkage.
3. Fuel lines at the TBI.
-Relieve fuel pressure, refer to the 1991 Light Duty Fuel and Emissions Manual, 4-17.
-Raise the vehicle.
4. Transmission fluid.
-Transfer case fluid (K model).
-Transfer case skid plate, if equipped (K model).
5. Shift linkage.
6. Propeller shaft, refer to PROPELLER SHAFT (SEC. 4A).
-Front propeller shaft from the transfer case (K model).
7. Electrical connector and transfer case vent tube (K model).
8. Transfer case shift linkage (K model). Refer to TRANSFER CASE (SEC. 7D).
9. Transfer case to adaptor mounting bolts (K model).
10. Transfer case (K model).
-Clean transfer case gasket mating surfaces.
11. Support bracket at the catalytic convertor.
-Any other components as needed for clearance.
12. Exhaust crossover at the manifolds.
13. Transmission mount and crossmember.
-Support the transmission with a transmission jack.
IMPORTANT:
Do not stretch or damage any cables, wires or other components when lowering the transmission.
14. Transmission far enough for clearance to reach other components.
15. Transmission fill tube and the seal.
16. Speedometer harness connector.
17. Electrical connectors from the transmission.
18. Transmission cooler lines.
-Cap all openings in the transmission and the lines.
19. Transmission to engine support braces.
-Note the location of the braces, they must be installed in the same positions.
20. Convertor housing cover.
21. Torque convertor to flywheel bolts.
IMPORTANT:
Support the engine with a jack or hoist before disconnecting the transmission.
22. Transmission to engine bolts.
-Note the location of any brackets or clips and move them aside.
-Slide the transmission straight back off of the locating pins and install J 21366.
23. Transmission from the vehicle.
-TV cable from transmission.
-Transfer case adaptor from transmission (K model).
Install
Tool Required:
J 21366 Convertor Holding Strap
1. New transmission.
-TV cable to transmission.
-Transfer case adapter to transmission (K model).
-Tighten transmission to transfer case adapter bolts to 33 N-m (24 lbs.ft.) (K model).
-Be sure the torque convertor is seated properly and that J 21366 is in place.
-Support the transmission with a transmission jack. Raise the transmission into place and remove J 21366.
-Slide the transmission straight onto the locating pins while lining up the flywheel to torque convertor bolt holes.
IMPORTANT:
The torque convertor must be flush onto the flywheel and rotate freely by hand.
2. Transmission to engine bolts.
-All brackets, clips and harnesses must be positioned as they were when removed.
-Remove the engine hoist or jack.
-Do not install the transmission fill tube or the transmission support braces at this time.
3. Torque convertor to flywheel bolts.
-Tighten bolts finger tight to ensure proper convertor seating.
-Torque bolts to 63 N-m (46 lbs.ft.).
4. Convertor housing cover.
-Hook the cover under the lip of the engine oil pan.
5. Transmission to engine support braces.
-The braces must be installed in the positions from which they were removed.
6. Transmission Cooler lines
-Do not twist or bend the lines.
7. Electrical connectors to the transmission.
8. Speedometer harness connector.
9. Transmission fill tube and seal.
10. Transmission mount to transmission.
-Tighten bolts to
11. Transmission crossmember.
-Tighten frame bolts to 77 N-m (56 lbs.ft.).
-Tighten mount bolt to 52 N-m (38 lbs.ft.).
-Remove transmission jack.
12. Exhaust crossover at the manifolds.
13. Support bracket at the catalytic convertor.
-Any other components removed for clearance.
14. Transfer case (K model).
-Install new adaptor gasket.
-Tighten transfer case to adapter bolts to 33 N-m (24 lbs.ft.)
15. Transfer case shift lever (K model).
16. Electrical connector and transfer case vent tube (K model).
17. Propeller shaft.
-Front propeller shaft to transfer case (K model).
18. Shift linkage.
19. Transmission fluid.
-Transfer case fluid (K model).
-Transfer case skid plate, if equipped (K model).
20. Fuel lines at the TBI.
21. TV cable at the throttle linkage.
22. Negative (-) battery cable.
23. Install "Campaign Identification Label".