Transmission Replacement

Transmission Replacement
^ Tools Required
- J 3289-20 Holding Fixture
- J 36842 Transmission Holding Fixture
- J 42055 Drivetrain Support Fixture
- J 36221 Hydraulic Clutch Line Separator

Removal Procedure





1. Remove the control assembly.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
3. Drain the transmission fluid.
4. Remove the propeller shaft.
5. Remove the torque arm.
6. Support the rear axle with jack stands.
7. Remove the catalytic converter.





8. Disconnect the wire harness connectors from the speed sensor (1) and the backup lamp switch (3) on the left side.
9. Remove the wiring harness clip bolt (2).





10. Remove the wiring harness clip bolt (1) from the right side.
11. Remove the starter motor.





12. Remove the left transmission brace bolts (2, 3).
13. Remove the left transmission brace (1).





14. Remove the right transmission brace bolts (2, 3, 4).
15. Remove the right transmission brace (1).





16. Remove the flywheel housing cover bolts (2).
17. Remove the flywheel housing cover (3) from the transmission (1).





18. Using J36221, depress the white circular release ring on the actuator cylinder hose and simultaneously pull lightly on the master cylinder hose to disconnect.
19. Protect both hose coupling ends from dirt and damage.
20. Support the engine with a safety stand.
21. Install the J 42055 to the transmission jack.
22. Support the transmission with the transmission jack.
23. Remove the transmission support and mount.





24. Remove the flywheel housing bolts (1, 2) and nuts (3).
25. Slowly lower the manual transmission (4) from the vehicle.
26. Remove the vent hose from the transmission.
27. Remove the clutch bleeder from the actuating cylinder.
28. Remove the clutch line from the actuating cylinder.





29. Remove the clutch actuator cylinder bolts (1).
30. Remove the clutch actuator cylinder (2).





31. Remove the transmission bolts (3).
32. Remove the bellhousing (1) from the transmission (2).
33. Install the J 36842 to the transmission, if necessary.
34. Remove the transmission from the transmission stand.
35. Install the transmission to the J 3289-20, if necessary.

Installation Procedure





1. Remove the transmission from the J 3289-20, if necessary.
2. Mount the transmission to the jack stand.
3. Remove the J 36842 from the transmission, if necessary.
4. Install the bellhousing (1) to the transmission (2).

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the transmission bolts (3).
^ Tighten the transmission bolts (3) to 75 Nm (55 ft. lbs.).





6. Install the clutch actuator cylinder (2).
7. Install the clutch actuator cylinder bolts (1).
^ Tighten the clutch actuator cylinder bolts (1) to 8 Nm (71 inch lbs.).
8. Install the clutch line to the actuating cylinder.
9. Install the clutch bleeder to the actuating cylinder.
10. Slowly raise the manual transmission (4) to the vehicle.
11. Install the flywheel housing bolts (1, 2) and nuts (3).
^ Tighten the flywheel housing bolts (1, 2) and nuts (3) to 95 Nm (70 ft. lbs.).
12. Install the transmission support and mount.
13. Remove the transmission jack.
14. Remove the J 42055 from the transmission jack.
15. Remove the engine safety stand.





Important: DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.

16. Connect the clutch actuator cylinder hose to the clutch master cylinder hose.
17. Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.
18. Check the clutch hydraulic hoses for twists or kinks.





19. Install the flywheel housing cover (3) to the transmission (1).
20. Install the flywheel housing cover bolts (2).
^ Tighten the flywheel housing cover bolts (2) to 9 Nm (80 inch lbs.).





21. Install the right transmission brace (1).
22. Install the right transmission brace bolts (2, 3, 4).
^ Tighten the right transmission brace bolts (2, 3, 4) to 50 Nm (37 ft. lbs.).





23. Install the left transmission brace (1).
24. Install the left transmission brace bolts (2, 3).
^ Tighten the left transmission brace bolts (2) (to transmission) to 50 Nm (37 ft. lbs.).
^ Tighten the left transmission brace bolts (3) (to engine) to 28 Nm (21 ft. lbs.).





25. Install the wiring harness clip bolt (1) to the right side of the transmission.
^ Tighten the wiring harness clip bolt (1 ) to 11 Nm (97 inch lbs.).





26. Install the wiring harness clip bolt (2) to the left side of the transmission.
^ Tighten the wiring harness clip bolt (2) to 11 Nm (97 inch lbs.).
27. Connect the speed sensor (1 ) and backup lamp switch (3) electrical connectors.
28. Install the catalytic converter.
29. Install the propeller shaft.
30. Install the torque arm.





31. Fill transmission with fluid.
32. Lower the vehicle.
33. Install the control assembly.
34. Bleed the clutch hydraulic system.