Installation
Transmission Replacement^ Tools Required
- J 42055 Transmission Support Fixture
Installation Procedure
Notice: Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
^ Tools Required
- J 42055 Transmission Support Fixture
1. Install the transmission to the J 42055, if removed.
2. Install the differential plate to the transmission, use care not to damage the transmission output seal in the rear of the plate.
3. Position the differential plate seal flush with the transmission case.
4. SLOWLY slide the differential to the transmission.
Notice: Refer to Fastener Notice in Service Precautions.
5. Install the differential to transmission bolts and nuts.
^ Tighten the differential to transmission bolts and nuts to 50 Nm (37 ft. lbs.).
6. Remove the strap retaining the transmission torque converter.
7. Slowly slide the driveline support assembly to the transmission, while supporting the transmission torque converter.
8. Install the transmission to driveline support assembly bolts/studs.
^ Tighten the transmission to driveline support assembly bolts/studs to 50 Nm (37 ft. lbs.).
9. Remove the caps from the rear of the transmission oil cooler rear pipes and remove the plugs from the fittings on the transmission.
10. ALIGN and HAND-START, then tighten ONLY by hand to seat the transmission oil cooler rear pipes to the fittings on the transmission.
^ Tighten the transmission oil cooler rear pipes to transmission fittings to 40 Nm (30 ft. lbs.).
11. Position the chainfall, or equivalent, of a lift device in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly.
Important: The aid of an assistant will be necessary for the following steps until the driveline is installed into the vehicle.
12. Using the lift device, raise the driveline off the workbench and position the driveline with the J 42055 onto a transmission jack.
13. Connect the J 42055 to the transmission jack.
14. Remove the lift device from the driveline.
15. Position the driveline under the vehicle.
16. Begin to raise the driveline at the approximate angle used during removal.
17. Position the wiring harness along the driveline support assembly and LOOSELY install the harness into the harness retaining slots.
18. Have an assistant guide the front of the driveline so the propeller input shaft is just to the rear of the engine flywheel housing, then raise the driveline to the PROPER HEIGHT and the PROPER ANGLE to install to the engine.
Important: Use care not to use too much force to install the propeller input shaft into the propeller shaft hub. The propeller input shaft front bearing positioning system is designed to withstand an insertion force not greater than 582 N (130 lb).
19. Have an assistant begin to insert the propeller input shaft into the propeller shaft hub while maintaining the proper angle of the driveline, if necessary use a screwdriver to rotate the shaft slightly to bring the splines into alignment.
20. SLOWLY seat the driveline to the engine flywheel housing while maintaining the proper angle of the driveline.
21. Reposition the wiring harness bracket from near the driveline tunnel wall to align with the appropriate driveline support assembly bolt hole.
22. Install the five driveline support assembly to engine flywheel housing bolts.
^ Tighten the driveline support assembly to engine flywheel housing bolts to 50 Nm (37 ft. lbs.).
23. Install the wiring harness to the wiring harness retainer along the top of the transmission.
24. SLOWLY raise the driveline to approximately 5 cm (2 inch) BELOW the final installed height.
25. Remove the caps from the front of the transmission oil cooler rear pipes and remove the plugs from the junction fittings at the engine flywheel housing.
26. ALIGN and HAND-START, then tighten ONLY by hand to seat the transmission oil cooler rear pipes to the junction fittings at the engine flywheel housing.
^ Tighten the transmission oil cooler rear pipes to junction fittings at engine flywheel housing to 27 Nm (20 ft. lbs.).
27. Install the transmission wiring harness to LH side of transmission case retaining bolt.
^ Tighten the transmission wiring harness to LH side of transmission case retaining bolt to 2.5 Nm (22 inch lbs.).
28. Connect the park/neutral position switch electrical connectors.
29. Connect the transmission harness 20-way connector.
Align the arrows on each half of the connector and insert straight down.
30. Connect the wiring harness clip to the top of the differential.
31. Connect the wiring harness retainer to the stud at the differential rear cover.
32. Connect the Vehicle Speed Sensor (VSS) electrical connector.
33. Slowly raise the driveline to final installation height.
34. Remove the jack which supported the engine.
35. Remove the tie-off retainers from the axle shafts.
36. CAREFULLY align and seat the axle shafts to the differential.
37. Install the transaxle mount and bracket to the differential.
38. Install the transaxle mount bracket to differential bolts.
^ Tighten the transaxle mount bracket to differential bolts to 50 Nm (37 ft. lbs.).
39. With the aid of an assistant, begin to raise the rear suspension crossmember (still firmly attached to a transmission jack), to the vehicle frame rails.
40. Guide the rear suspension crossmember alignment pins into the alignment holes in the vehicle frame rails, and guide the transaxle mount studs into the mounting holes in the crossmember, then raise the crossmember to seat to the frame rails.
41. Using ONLY HAND TOOLS, install NEW rear suspension crossmember mounting nuts.
^ Tighten the rear suspension crossmember mounting nuts to 110 Nm (81 ft. lbs.).
42. Remove the transmission jack from the rear suspension crossmember.
43. Release the J 42055 from the transmission, then remove the J 42055 and transmission jack.
44. Install the transaxle mount to rear suspension crossmember nuts.
^ Tighten the transaxle mount to rear suspension crossmember nuts to 50 Nm (37 ft. lbs.).
45. Install the differential to transmission lower nut.
^ Tighten the differential to transmission lower nut to 50 Nm (37 ft. lbs.).
46. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
47. Support the lower control arm with a straight jack.
48. Connect the lower ball joint to the suspension knuckle.
49. Install the shock absorber lower mounting bolt.
^ Tighten the rear shock absorber lower mounting bolt to 220 Nm (162 ft. lbs.).
50. Connect the outer tie rod end to the suspension knuckle.
51. Remove the straight jack from the suspension control arm.
52. Repeat steps 45 through 49 for the other side of the vehicle.
53. Install the rear transverse spring.
54. Carefully pull the wiring harness down into the L-shaped brackets along the driveline support assembly, align the harness retainer (locator) (1) to the hole in the forward bracket, then secure in place.
55. Install the transmission shift cable and bracket into position.
56. Connect the transmission shift cable to the transmission shift lever.
Press to secure the cable.
57. Install the nuts retaining the transmission shift cable bracket to the transmission.
^ Tighten the transmission shift cable bracket retaining nuts to 20 Nm (15 ft. lbs.).
Important: The following step must be performed to assure proper torque converter balance during installation.
58. Align the transmission flexplate to the transmission torque converter using the matchmark made prior to removal.
59. Install the transmission flexplate to transmission torque converter bolts.
60. Install the rear bellhousing access plug.
61. HAND-TIGHTEN the propeller shaft hub clamp bolt (1) until FINGER-TIGHT.
62. Remove the propeller input shaft front bearing positioning bolts (M10 -1.5 X 55 mm) from the driveline support assembly.
63. Install the two plug bolts to the front of the driveline support assembly.
^ Tighten the driveline support assembly front plug bolts to 50 Nm (37 ft. lbs.).
64. Install the driveline tunnel closeout panel.
65. Remove the tie-off retainer from the LH muffler assembly.
66. Install the RH muffler assembly.
67. Install the catalytic converter pipe assembly.
68. Install the rear tire and wheel assemblies.
69. Lower the vehicle.
70. Connect the negative battery cable.
^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).
71. Program the transmitters.
Important: The following steps MUST be performed in order to provide proper alignment of the propeller shaft hub, the propeller input shaft and the propeller input shaft front bearing.
72. Start and run the engine at idle until normal operating temperatures are reached.
(Idle or drive for at least 10 minutes.)
73. Turn off the engine and allow the powertrain to cool to ROOM temperature.
74. Raise the vehicle.
75. Tighten the propeller shaft hub clamp bolt (1).
^ Tighten the propeller shaft hub clamp bolt to 130 Nm (96 ft. lbs.).
76. Install the engine flywheel housing access plug.
77. Flush the transmission oil cooler.
78. Lower the vehicle.