Manual Transmission/Transaxle: Service and Repair

1. Disconnect battery ground cable.
2. Remove air cleaner and starter motor.
3. Remove two upper transmission mounting bolts from bellhousing.
4. On models equipped with a console box, remove lock screws and lift up console box.
5. On models not equipped with a console box, remove backbone carpet.
6. On all models, remove attaching screws and lift out dust cover retaining plate.
7. Turn up dust cover and remove control housing attaching bolts from extension housing, then remove control lever assembly.
8. Raise and support vehicle, then drain transmission oil.
9. Remove propeller shafts and disconnect speedometer cable.
10. Disconnect back-up light switch harness and, on 4 wheel drive models, the 4 wheel drive indicator light switch harness.
11. Disconnect front exhaust pipe.
12. On models with gasoline engine, disconnect clutch cable from clutch control lever.
13. On models with diesel engine, remove clutch release cylinder.
14. On all models, support rear of engine with suitable jack.
15. On models with 4 wheel drive, disconnect plate and remove transfer case mounting bracket.
16. On all models, using suitable jack, support transmission and remove No. 2 crossmember. Transmission supporting area should be as wide as possible.
17. Remove bellhousing cover, then the remaining transmission mounting bolts.
18. Withdraw transmission from engine, being careful not to twist front end of main drive gear.
19. Lower jack and remove transmission from under vehicle.
20. Reverse procedure to install, noting the following:
a. On 1984-86 models, torque bolts as follows on rear wheel drive models: transmission mounting bolts, 31-40 ft. lbs.; transmission to insulator nut, 15-17 ft. lbs.; and starter motor mounting nuts, 16-23 ft. lbs.
b. On 1984-86 models, torque bolts as follows on 4 wheel drive models: transmission mounting bolts, 31-40 ft. lbs.; transmission to rear insulator, 14-18 ft. lbs.; starter motor mounting bolts, 16-23 ft. lbs.; frame to plate bolts, 14-18 ft. lbs.; transfer case support insulator to transfer case mounting bracket bolts, 14-18 ft. lbs.; and transfer case mounting bracket to transfer case bolts, 14-18 ft. lbs.
c. On 1987-88 rear wheel drive models, torque 10 x 40 mm and 10 x 65 transmission mounting bolts to 31-40 ft. lbs., 8 x 25 mm and 8 x 55 mm transmission mounting bolts to 15-20 ft. lbs. and 10 x 60 mm mounting bolts to 16-23 ft. lbs.
d. On 1987-88 4 wheel drive models, torque torque 10 x 40 mm transmission mounting bolts to 31-40 ft. lbs., 8 x 25 mm and 8 x 55 mm and 10 x 65 mm transmission mounting bolts to 15-20 ft. lbs. and 10 x 60 mm mounting bolts to 16-23 ft. lbs.
e. When installing control lever assembly on rear wheel drive models, place gearshift lever in 2nd speed position on 4 speed transmission, or in 1st speed position on 5 speed transmission.
f. When installing gearshift lever assembly on 4 wheel drive models, set transmission gearshift lever to Neutral position and transfer case gearshift lever to ``4H'' position.
g. Ensure bellhousing cover is not bent.
h. Install dust cover onto tunnel hole, then install retaining plate with attaching screws.
i. Adjust clutch and fill transmission to specifications with suitable fluid.