Transmission Replacement

REMOVAL

1. Remove shift lever knobs from transmission and transfer case shifter levers.
2. Remove transmission and transfer case shift lever boots.
3. On models with AX-5 transmission, press stub shaft retainer downward and rotate counterclockwise to release from lugs, then lift shift lever, stub shaft and retainer from transmission. Do not remove shift lever from stub shaft.
4. On models with BA 10/5 transmission, remove shift tower dust boot, then remove stub shaft retainer plate and lift stub shaft and shifter lever from transmission. On some units, a snap ring may be used in place of the retainer plate. Do not separate shift lever from stub shaft.
5. On all models, raise and support vehicle.
6. Drain lubricant from transmission and transfer case.
7. Place alignment marks on rear propeller shaft for reference during installation, then remove propeller shaft from vehicle.
8. Position a safety stand under transfer case for support, then remove rear crossmember.
9. Disconnect speedometer cable and back-up lamp switch from transmission.
10. Disconnect and tag vent and vacuum hoses from transmission and transfer case.
11. Disconnect range linkage from transfer case.
12. Place alignment marks on front propeller shaft for reference during installation, then remove propeller shaft.
13. Disconnect clutch master cylinder line from slave cylinder.
14. Position a suitable transmission jack under transmission and transfer case and secure with safety chains.
15. Remove clutch housing brace rod and clutch housing-to-engine attaching bolts, then lower transmission and transfer case from vehicle.
16. If necessary, remove bolts attaching transfer case to transmission and separate.
17. Remove clutch slave cylinder and throw-out bearing from transmission, then remove clutch housing.

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.