Unit Removal and Installation
REMOVAL PROCEDURE1. Shift the transmission into the 3rd or 4th mechanical gear position.
2. Remove the shift lever. Refer to Shift Lever.
3. Remove the shift housing. Refer to Shift Tower Replacement.
4. Raise and support the vehicle.
5. Remove the park brake cable. Refer to Park Brake.
6. Remove the propeller shaft. Refer to Propeller Shaft.
7. Disconnect the wiring harness connectors from the vehicle speed sensor and back up switch.
8. Disconnect the wiring harness retainers from the right side of the transmission.
9. Remove the muffler from the catalytic converter. Refer to Exhaust System.
10. Remove the exhaust pipes from the exhaust manifold. Refer to Exhaust System.
11. Remove the catalytic converter hanger. Refer to Exhaust System.
12. Remove three bolts, two nuts and washers securing the transfer case shield to the frame rail and transmission (If the vehicle is equipped with four wheel drive).
13. For the NV3500 only, remove the bolt securing the left side brace to the transmission.
14. For the NV3500 only, remove the bolt and stud securing the left side brace to the transfer case.
15. For the NV3500 only, remove the bolt securing the right side brace to the transmission.
16. For the NV3500 only, remove the bolt securing the right side brace to the transfer case.
17. For the NV1500 only, remove two bolts securing right side brace to the engine and transmission.
18. For the NV1500 only, remove two bolts and a nut securing the left side brace to the engine and transmission.
19. Remove the transfer case, if equipped. Refer to Transfer Case.
20. Disconnect the hydraulic clutch line quick connect from the concentric slave cylinder.
21. Use special tool J36221 to depress the white plastic sleeve on the quick connect to separate the clutch line end from the concentric slave cylinder quick connect.
22. Remove four bolts securing the clutch housing cover to the transmission.
23. Remove the clutch plate and clutch cover from the flywheel. Refer to Clutch Assembly Replacement.
24. Support the transmission with a jack.
25. Remove the fuel lines and fuel line retainers from the rear crossmember. Refer to Fuel System.
26. Remove the rear crossmember from the frame rail.
27. Remove the wiring harness from the front crossmember.
- Move the wiring harness away from the transmission oil pan.
- Lower the transmission enough to gain access to the top of the transmission.
28. Remove the fuel line retainers from the top of the transmission.
29. For the NV1500 only, remove the bolt, washer, and nut securing the wiring harness ground wires to the engine block.
30. Remove five bolts securing the transmission to the engine.
Pull the transmission straight back on the clutch hub spines.
31. Lower the transmission using the transmission jack.
INSTALLATION PROCEDURE
1. Raise the transmission using the transmission jack.
2. Place the fuel line retainers on top of the transmission.
3. Install the transmission to the engine and secure with bolts.
Push the transmission straight back onto the clutch hub spines.
Tighten the transmission to the engine bolts to 90 Nm (66 ft. lbs.).
4. Install the bolt, washer and nut securing the wiring harness ground wires to the engine block.
5. Install the hydraulic clutch line to the concentric slave cylinder quick connect.
6. For the NV1500 only, install two bolts securing the transmission right side brace to the engine and transmission.
Tighten the right side brace bolts to 50 Nm (37 ft. lbs.).
7. For the NV1500 only, install two bolts and a nut securing the transmission left side brace to the engine and transmission.
Tighten the left side brace bolts and nut to 50 Nm (37 ft. lbs.).
8. For the NV3500 only, install the bolt and stud securing the transmission left side brace to the transfer case.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).
9. For the NV3500 only, install the left side brace to the transmission with the bolt.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).
10. For the NV3500 only, install the right side bract to the transmission with the bolt.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).
11. For the NV3500 only, install the bolt securing the right side brace to the transfer case.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).
12. Install the catalytic converter hanger and exhaust section. Refer to Exhaust System.
13. Install the exhaust pipes to the exhaust manifold. Refer to Exhaust System.
14. Connect the muffler to the catalytic converter. Refer to Exhaust System.
15. Install the wiring harness retainers to the right side of the transmission.
16. Install the wiring harness connectors to the vehicle speed sensor and back up switch.
17. Install the propeller shaft. Refer to Propeller Shaft.
18. Install the park brake cable. Refer to Park Brake.
19. Install the shift housing. Refer to Shift Tower Replacement.
20. Install the shift lever. Refer to Shift Lever.