Removal
Transmission-4x4
Special Tool(s)
All vehicles
1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they can experience slightly different upshifts either (soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.
Disconnect the battery ground cable.
2. Remove the fan shroud bolts. Do not remove the fan shroud.
3. Raise and support the vehicle.
4. If transmission disassembly or installation of new transmission is necessary, drain the transmission fluid.
^ Install the drain plug when finished.
5. Remove the 2 RH heat shield bolts and position the RH heat shield aside.
6. Disconnect the 2 heated oxygen sensor electrical connectors.
7. Disconnect the 2 catalyst monitor sensor electrical connectors.
8. Remove the RH heat shield bolts.
9. Remove the RH heat shield bolt and remove the heat shield.
10. Remove the LH heat shield bolt.
11. Remove the plastic shield on the right side of the crossmember near the fuel tank.
12. NOTE: RH side shown, LH side similar.
Remove the 2 upper crossmember bolts (2 on each side).
13. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
^ Discard the gasket.
^ Discard the flag nuts.
14. NOTE: LH side shown, RH similar.
Remove the 4 converter-to-manifold nuts.
15. Install a suitable jackstand under the transfer case.
16. Remove the RH side crossmember bolts.
17. Remove the LH side crossmember bolts.
18. Remove the transmission support insulator nuts and remove the crossmember.
19. NOTE: This step may require an assistant.
Remove the transmission mounted exhaust hanger and the 3-way converter system.
1 Remove the bolt and converter assembly.
2 If required, remove the 2nd bolt and mount.
20. Remove the shift cable and bracket.
21. Position the manual lever out of park.
22. Index-mark the front axle pinion flange and the front driveshaft.
23. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint.
24. Remove and discard the bolts and washers.
25. Remove and discard the bolts and universal joint retainers.
26. CAUTION: Always disconnect the front driveshaft from the transfer case 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.
NOTE: The front driveshaft CV joint is not repairable.
Remove the driveshaft.
27. NOTE: The pinion flange is shown, transfer case flange is similar.
Remove the rear driveshaft bolts.
1 Mark the location of the flanges.
2 Remove the 8 bolts.
28. NOTE: Do not use a hammer.
Remove the driveshaft from the flange using a pry bar.
4.6L engine
29. Remove the electrical connector cover.
30. Remove the starter wire and the positive battery cable.
31. Remove the starter motor bolts and starter.
32. Remove the flexplate cover.
33. Remove the access cover.
34. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
Remove the 4 torque converter nuts.
4.0L engine
35. Remove the starter and position off to the side.
36. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
Remove the 4 torque converter nuts.
37. Remove the lower transmission retaining bolts.
All vehicles
38. Lower the transmission to gain access to the sensor connectors and the transmission bolts.
39. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.
40. Disconnect the RH heated oxygen sensor from the transmission.
41. If equipped, disconnect the shift motor electrical connector.
42. Disconnect the LH heated oxygen sensor and the harness clip from the transmission.
43. Disconnect the LH catalyst monitor connector from the transmission.
44. Move the rubber boot back to gain access to the connector.
45. Disconnect the digital Transmission Range (TR) sensor connector.
46. Disconnect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor and Intermediate Shaft Speed (ISS) sensor electrical connectors.
47. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
Remove the screw from the solenoid body connector and disconnect the connector.
48. Disconnect the harness retainers.
49. CAUTION: Do not damage the cooler tubes. Hold the transmission case fittings with a wrench.
Disconnect the transmission cooler tubes.
50. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
Support the transmission with a transmission jack.
51. Remove the jackstand from under the transfer case.
4.6L engine
52. NOTE: RH side shown, LH side similar.
Remove the 4 front crossmember bolts and the crossmember.
53. Remove the 7 engine-to-transmission retaining bolts.
4.0L engine
54. Remove the 6 engine-to-transmission retaining bolts and position the fuel line bracket aside.
All vehicles
55. Lower the transmission and transfer case as an assembly from the vehicle.
56. Install the special tool.
57. NOTE: If the transmission is being serviced, the transfer case will need to be removed.
Remove the transfer case from the back of the transmission.
^ Remove the bolts and the bracket.
^ Disconnect the vent hose.
58. Carry out the transmission fluid cooler backflushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission.