Transmission Replacement

Transmission Replacement
Removal Procedure





1. Shift the transmission into 3rd or 4th gear.
2. Remove the shift lever from the shift tower.
3. Do not remove the shift lever adjusting nut.





4. Remove 4 plastic retainer plugs securing the shift boot retainer to the shift boot.
5. Remove the 4 screws securing the shift boot and insulator to the floor panel.
6. Remove the retainer and shift boot from the shift lever.





Important:
^ Ensure that the shift lever is positioned into the mechanical third or fourth gear prior to removal of the shift housing from the transmission. The transmission must remain in this state when the shift housing is removed.
^ When removing the shift housing from the transmission, use the exposed bolts on the base of the housing.

7. Remove the shift lever.
8. With a flat tool pull back the insulator to access the shift tower bolts.
9. Remove the 4 shift tower bolts securing the shift housing to the transmission.
10. Turn and release the shift tower and pull through the insulator.





Important: The clutch hydraulic hose can remain attached to the clutch actuator. Disconnecting the hose from the clutch actuator will cause the fluid to drain from the hydraulic system.

11. Disconnect the hydraulic hose at the quick disconnect from the master cylinder.
12. Remove the retainers that support the hydraulic line.
13. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





14. Drain the transmission oil.
15. Remove the rear propeller shaft.
16. Remove the transfer case, if equipped.





17. Remove the exhaust support bracket and the 2 bolts from the transmission.





18. Remove the front fuel line nut and bracket from the manual transmission.





19. Remove the rear fuel line bolt and bracket from the manual transmission.
20. Disconnect the following electrical connectors:
^ Vehicle speed sensor
^ Backup lamp switch
21. Remove the transmission wiring harness from the retainers.
22. Support the manual transmission with a suitable transmission jack.
23. Remove the crossmember.





24. Remove the bolts and studs securing the transmission to the engine. Note the location of the studs and the bolts.
25. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.
26. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
27. Remove the insulator from the top of the transmission.
28. Remove the 2 bolts or nuts holding the clutch actuator.

Important: Leave the clutch actuator hose attached to the clutch actuator. Disconnecting the hose from the clutch actuator will let the hydraulic fluid drain from the clutch hydraulic system.





29. Remove the clutch actuator from the transmission with the clutch hydraulic line attached.
30. Remove the clutch plate and the clutch cover from the engine flywheel it required.

Installation Procedure





1. If removed, install the clutch plate and the clutch cover to the engine flywheel if removed.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the clutch actuator to the transmission with the clutch hydraulic line attached.
^ Tighten the clutch actuator bolts or nuts to 8 Nm (71 inch lbs.).





3. Shift the transmission in 3rd or 4th speed gear.
4. Install the insulator to the top of the transmission.
5. Use the following steps to install the transmission.
5.1. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
5.2. Rotate the transmission clockwise onto the clutch hub splines.
5.3. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
6. Install the bolt and the studs securing the transmission to the engine. Ensure the bolts and studs are installed in the correct locations.
^ Tighten the transmission bolts and studs to 50 Nm (37 ft. lbs.).
7. Install the crossmember.





8. Install the rear fuel line bracket and bolt.
^ Tighten the rear fuel line bolt to 30 Nm (22 ft. lbs.).





9. Install the front fuel line bracket and nut.
^ Tighten the nut to 30 Nm (22 ft. lbs.).
10. Install the wiring harness retainers.





11. Install the wire harness.
12. Connect the backup switch and the vehicle speed sensor.





13. Install the 2 bolts securing the right side support bracket to the manual transmission.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
14. If equipped with a 4WD, install the front propeller shaft.
15. If Rear Wheel Drive (RWD), Install the rear propeller shaft.





16. Fill the transmission with fluid.
17. Lower the vehicle.





18. Push the shift tower back through the insulator, position and turn the shift tower back into place.
With a flat tool pull back the insulator to install the shift tower bolts.
Install the 4 bolts securing the shift housing to the transmission.
^ Tighten the shift housing bolts to 23 Nm (17 ft. lbs.).





19. Position the retainer and shift boot onto the shift lever.
20. Install the 4 screws securing the shift boot and insulator to the floor panel.
^ Tighten the screws to 2 Nm (18 inch lbs.).
21. Install 4 plastic retainer plugs securing the shift boot retainer to the shift boot.





22. Install the shift lever to the shift tower.
If required, use the shift lever adjusting nut to center the shift lever.
^ Tighten the shift lever nut to 47 Nm (35 ft. lbs.).





23. Quick connect the hydraulic line to the master cylinder.

Important: Improper connection may cause the quick connect from locking properly. Before pushing in the clutch pedal fully, check with light pressure. If pedal is hard recheck connection.

24. Install new retainers to support the hydraulic line.