Transmission Assembly Removal and Replacement

REMOVE OR DISCONNECT
- Shift the transmission into 3rd or 4th mechanical gear position.

1. Shift lever and boot.
2. Shift housing.
- Raise and support the vehicle.
3. Transmission oil.
4. Propeller shaft.
5. Transfer case, if the vehicle is equipped with four wheel drive.
6. Parking brake and controls, if the vehicle is equipped.
7. Exhaust pipes from the exhaust manifold and catalytic converter from the muffler assembly, if required.
8. Wiring harness connectors from the speed sensor and backup lamp switch.
9. Wiring harness retainers from the transmission.





10. Clutch line from the concentric slave cylinder quick connect coupling.
- Use special tool J 36221 to depress the white plastic sleeve on the quick connect coupling to separate the hydraulic clutch line end from the quick connect coupling.
11. Starter.





12. Four bolts securing the clutch housing cover to the transmission.

13. Bolts securing the crossmember to the frame rails.
- Support the transmission with a transmission jack.
- Support the engine with a jack.
14. Clutch plate and clutch cover from the flywheel.





15. Bolts and studs securing the transmission to the engine.
- Pull the transmission straight back on the clutch hub splines.
- Do not let the transmission hang from the clutch and clutch cover plates.
- Do not let the clutch and clutch cover plates drop from the transmission.
- Remove the clutch and clutch cover plates during transmission to engine separation.
16. Using the transmission jack, lower the transmission to the floor.

INSTALL OR CONNECT
1. Ensure the clutch and clutch cover plates are positioned correctly onto the transmission main shaft.
2. Raise the transmission using a transmission jack.
- Do not let the clutch and clutch cover plates drop from the transmission.
3. Transmission to the engine.
- Push the transmission straight back onto the clutch hub splines.
- Do not force the transmission into the clutch hub splines.
- Do not let the transmission hang from the clutch and clutch cover plates.
- Keep the jack under the transmission to support it.
4. Bolts and studs securing the transmission to the engine.
- Tighten bolts and studs securing the transmission to the engine to 47 Nm (35 ft. lbs.).
5. Clutch and clutch cover plates to the flywheel.
- Lower and remove the jack
6. Four bolts securing the clutch housing cover to the transmission.
- Tighten clutch housing cover bolts to 10 Nm (89 inch lbs.).
7. Starter.
8. Bolts securing the crossmember to the frame rails.
- Tighten crossmember bolts to 51 Nm (38 ft. lbs.).
9. Hydraulic clutch line to the concentric slave cylinder quick connect coupling.
10. Exhaust pipes to the exhaust manifold and catalytic converter to the muffler assembly if required.
11. Wiring harness retainers to the transmission.
12. Wiring harness connectors to the speed sensor and back up switch.
13. Transfer case, if the vehicle is equipped with four wheel drive.
14. Propeller shaft.
15. Parking brake and controls, if the vehicle is equipped.
16. New transmission oil.
- Lower the vehicle.
17. Shift housing.
18. Shift lever.