Transmission Replacement

Transmission Replacement

^ Tools Required
- J 42371 Clutch Line Removal Tool

Removal Procedure





1. Shift the transmission into 3rd or 4th speed gear.
2. Remove the shift lever.
3. Remove the shift tower.
4. Drain the transmission oil.
5. If equipped with a transfer case, remove the front propeller shaft.
6. Remove the rear propeller shaft.
7. If equipped, remove the two transfer case shields.
8. If equipped with a manual transfer case, remove the manual transfer case shift linkage.
9. If equipped with a transfer case, remove the bolt securing the left side support brace to the transmission.





10. If equipped with a transfer case, remove the bolt and stud securing the left side support brace to the transfer case.





11. If equipped with a transfer case, remove the bolt securing the right side support brace to the transmission.





12. If equipped with a transfer case, remove the bolt securing the right side support brace to the transfer case.





13. Use the J 42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the clutch actuator quick connect.
14. Disconnect the wiring harness and connector from the vehicle speed sensor, backup lamp switch, and transmission harness retainers.





15. If equipped with a 4.3 L engine, remove the 2 bolts securing the clutch housing cover.
16. Remove the transmission rear mount.
17. Support the transmission with a transmission jack.





18. Remove the bolts securing the bottom right side of the transmission to the engine.
^ Bolt (1) secures the clutch housing cover on 4.3 L engines only.
^ Bolt (2) is used on engines larger than 4.3 L.





19. Remove the stud securing the right side of the transmission to the engine.





20. Remove the bolt and 6 studs securing the transmission to the engine.
21. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.
22. Remove the transmission from the vehicle.
23. Remove the clutch plate and the clutch cover from the engine flywheel if required.

Installation Procedure





1. 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 transmission:
2.1. Ensure the transmission is positioned in the 3rd or 4th speed gear.
2.2. Rotate the transmission clockwise onto the clutch hub splines.
2.3. Install the bolt and the studs securing the transmission to the engine.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





3. Install the stud securing the right side of the transmission to the engine.
^ Tighten the stud to 50 Nm (37 ft. lbs.).





4. Install the bolts securing the bottom right side of the transmission to the engine.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
^ Bolt (1) secures the clutch housing cover on 4.3 L engines only.
^ Bolt (2) is used on engines larger than 4.3 L.





5. If equipped with a 4.3 L engine, install the clutch housing cover using the 2 bolts.
^ Tighten the bolts to 14 Nm (10 ft. lbs.).
6. Install the transmission rear mount.
7. Install the clutch line to the clutch actuator.





8. If equipped with a transfer case, install the bolt securing the right side support brace to the transmission.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





9. If equipped with a transfer case, install the bolt securing the right side support brace to the transfer case.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





10. If equipped with a transfer case, install the bolt and stud securing the left side support brace to the transfer case.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





11. If equipped with a transfer case, install the bolt securing the left side support brace to the transmission.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
12. If equipped with a manual transfer case, install the manual transfer case shift linkage.
13. If equipped, installed the 2 transfer case shields.
14. If equipped with a transfer case, install the front propeller shaft.
15. Install the rear propeller shaft.
16. Install the shift tower.
17. Fill the transmission with transmission fluid.
18. Install the shift lever.