Transmission Replacement

REMOVAL
1. Shift transmission into first or third gear, then raise and support vehicle.
2. Support engine with adjustable jack stand, then disconnect necessary exhaust system components.
3. Disconnect rear transmission mount and bracket from transmission, then remove skid plate or rear crossmember.
4. Disconnect transfer case shift linkage, vehicle speed sensor wires and vent hose.
5. Disconnect clutch hydraulic lines.
6. Disconnect transmission shift lever as follows:
a. Lower transmission/transfer case assembly approximately three inches for access to shift lever.
b. Reach around transmission and unseat shift lever dust boot from shift tower. Move boot up on lever.
c. Reach around transmission and press shift lever retainer downward with fingers. Turn retainer counterclockwise to release it.
d. Lift lever and retainer out of shift tower. Do not remove shift lever from floorpan boots.

7. Mark front and rear propeller shafts for installation alignment, then remove shafts.
8. Remove crankshaft position sensor, if equipped.
9. Disconnect vehicle speed sensor connector, then the transmission/transfer case vent hoses.
10. Disconnect clutch master cylinder hydraulic line from concentric bearing inlet line.
11. Support transmission/transfer case with suitable jack, then install safety chains.
12. Remove clutch housing to engine bolts, then remove transmission/transfer case assembly.
13. Separate transfer case from transmission, then remove concentric bearing and clutch housing from transmission.


INSTALLATION
1. Install clutch housing on transmission. Tighten to specifications.
2. Install concentric bearing. Secure bearing to mounting pin with new retainer clip.
3. Mount transmission on suitable jack, then lightly lubricate pilot bearing and input shaft splines with high temperature grease.
4. Align transmission input shaft and clutch disc splines, then install transmission.
5. Install clutch housing to engine bolts and tighten to specifications. Ensure housing is properly seated.
6. Lower transmission approximately three inches. Ensure transmission is in first or third gear.
7. Reach around transmission and insert shift lever in shift tower. Press lever retainer downward and turn it clockwise to lock in place, then install lever dust boot on shift tower.
8. Connect concentric bearing hydraulic line and engine timing sensor connector.
9. Remove jack from under transmission and mount transfer case on jack.
10. Align transfer case and transmission shafts, then install transfer case. Tighten transfer case to transmission nuts and bolts to specifications.
11. Remove jack stand from under engine and reposition it under transmission, then remove transmission jack.
12. Connect transfer case shift linkage. Adjust linkage if necessary.
13. Connect transmission and transfer case vent hoses, then the back-up light switch and vehicle speed sensor connectors.
14. Install and connect crankshaft position sensor, if equipped.
15. Install rear crossmember or skid plate, then the propeller shafts.
16. Lower vehicle and check fluid level.