Transmission Replacement

REMOVAL

1. Remove transmission shift lever boot attaching screws and slide boot upward.
2. On models with SR-4, T4 or T5 transmissions, remove bolts attaching transmission shift lever housing to transmission. Lift shift lever and housing upward and out of transmission.
3. On models with T-18A transmission, remove shift lever cap, gasket, spring seat, spring and shift lever as an assembly, then remove shift lever locating pins from housing.
4. On models with T-176 transmission, press and rotate transmission shift lever retainer, then remove lever, boot, spring and seat as an assembly.
5. On all models, raise vehicle, then place alignment marks on propeller shaft and transfer case yoke. Disconnect propeller shaft at transfer case yoke and secure to underbody with wire.
6. On truck models, disconnect front parking brake cable at equalizer, then remove clip that retains rear cable to rear crossmember and position cable out of way.
7. On all models, support engine by positioning a jack stand under clutch housing.
8. Remove bolts and nuts attaching rear crossmember to frame side rails and support cushion, then remove crossmember.
9. Disconnect speedometer cable, back-up lamp switch wire and four wheel drive indicator switch wire.
10. Disconnect transfer case vent hose at transfer case.
11. Place alignment marks on front propeller shaft and transfer case yoke, then disconnect propeller shaft and secure to underbody with wire.
12. On truck models, remove cotter pin and washer that connect link to shift lever, then disconnect link.
13. On all models, using a suitable jack, support transmission and transfer case assembly.
14. Remove transmission to clutch housing attaching bolts, then remove transmission and transfer case assembly.
15. Reverse procedure to install. Soak pilot bushing lubricating wick in engine oil before installing.

INSTALLATION

1. Install clutch housing on transmission, torque attaching bolts to 27 ft. lbs.
2. Install clutch slave cylinder and throw-out bearing.
3. Position transmission on suitable transmission jack, then align transmission input shaft splines with spline on clutch plate. Install transmission and torque clutch housing to engine attaching bolts to 28 ft. lbs.
4. Connect clutch master cylinder line to slave cylinder.
5. Position transfer case on suitable transmission jack, then align transfer case and transmission shaft splines.
6. Install transfer case on transmission and torque attaching bolts to 26 ft. lbs.
7. Remove transmission jack from transfer case and position a safety stand under transfer case for support.
8. Connect vacuum hose, vent hoses, back-up light switch, speedometer cable and transfer case range linkage.
9. Install rear crossmember. Torque crossmember to frame attaching bolts to 30 ft. lbs. Torque rear support to transmission attaching bolts and nuts to 33 ft. lbs.
10. On models equipped with AX-5 transmission, install shift lever, stub shaft and retainer on transmission tower. Lock retainer by rotating clockwise until lug are fully engaged. When installing, ensure nylon insulator at end of stab shaft is properly seated in shifter block located inside transmission tower.
11. On models equipped with BA 10/5 transmission, position shift lever and stub shaft on transmission tower, then install retaining plate or snap ring, depending on unit.
12. On all models, install shift tower dust boot and shift lever boots and knobs.
13. Install front and rear propeller shafts, aligning marks made during removal. Torque U-clamp bolts to 170 inch lbs.
14. Fill transmission and transfer case with lubricant and lower vehicle.