Transmission Replacement

Transmission Replacement

^ Tools Required
- J 42371 Clutch Line Removal Tool

Removal Procedure





1. Shift the transmission into the 3rd or 4th mechanical gear position.
2. Remove the shift lever.
3. Remove the shift housing.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Remove the rear propeller shaft.
6. Remove the front propeller shaft.
7. Disconnect the wiring harness connectors from the vehicle speed sensor and back up switch.
8. Disconnect the wiring harness retainers from the right side of the transmission.
9. Remove the catalytic converter Catalytic Converter Replacement (2.2 L) or Catalytic Converter Replacement (4.3 L Pickup) or Catalytic Converter Replacement (4.3 L Utility) in Engine Exhaust.
10. Remove 3 bolts, 2 nuts and washers securing the transfer case shield to the frame rail and transmission (If the vehicle is equipped with 4WD).





11. Remove the bolt securing the left side brace to the transmission.





12. Remove the bolt and stud securing the left side brace to the transfer case.





13. Remove the bolt securing the right side brace to the transmission.





14. Remove the bolt securing the right side brace to the transfer case.
15. Remove the transfer case, if equipped.





16. Disconnect the hydraulic clutch line quick connect from the clutch actuator.
17. Use J 42371 to depress the white plastic sleeve on the quick connect, to separate the clutch line end from the clutch actuator quick connect.
18. Remove 4 bolts securing the clutch housing cover to the transmission.
19. Support the transmission with a jack.
20. Remove the wiring harness from the front crossmember.
21. Lower the transmission enough to gain access to the top of the transmission.
22. Remove the fuel line retainers from the top of the transmission.





23. Remove the bolt, washer, and nut securing the wiring harness ground wires to the engine block.
24. Remove 5 bolts securing the transmission to the engine.
Pull the transmission straight back on the clutch hub splices.
25. Lower the transmission using the transmission jack.

Installation Procedure
1. Raise the transmission using the transmission jack.
2. Place the fuel line retainers on top of the transmission.

Notice: Refer to Fastener Notice in Service Precautions.





3. Install the transmission to the engine and secure with bolts.
^ Push the transmission straight back onto the clutch hub splines.
^ Tighten the transmission to the engine bolts.
Tighten
Tighten the bolts to 47 Nm (35 ft. lbs.).
4. Install the bolt, washer and nut securing the wiring harness ground wires to the engine block.
5. Install the housing cover and bolt.
Tighten the clutch housing cover bolts to 14 Nm (10 ft. lbs.).





6. Install the hydraulic clutch line to the clutch actuator quick connect.
7. Install the transfer case if equipped.





8. Install 2 bolts securing the transmission right side brace to the engine and transmission.
Tighten the right side brace bolts to 50 Nm (37 ft. lbs.).
9. Install 2 bolts and a nut securing the transmission left side brace to the engine and transmission.
Tighten the left side brace bolts and nut to 50 Nm (37 ft. lbs.).





10. Install the bolt and stud securing the transmission left side brace to the transfer case.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).





11. Install the left side brace to the transmission with the bolt.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).





12. Install the right side brace to the transmission with the bolt.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).





13. Install the bolt securing the right side brace to the transfer case.
Tighten the left side brace bolt and stud to 50 Nm (37 ft. lbs.).
14. Install the catalytic converter hanger and exhaust section.
15. Install the exhaust pipes to the exhaust manifold.
16. Connect the muffler to the catalytic converter.
17. Install the wiring harness retainers to the right side of the transmission.
18. Install the wiring harness connectors to the vehicle speed sensor and back up switch.
19. Install the front propeller shaft.
20. Install the propeller shaft.
21. Install the shift housing.
22. Install the shift lever.