Transmission Replacement (Installation)
Installation ProcedureNotice: When tilting down the rear of the driveline, insert a putty knife or similar tool between the shift control bracket on the driveline support assembly and the brake pipe retainer on the driveline tunnel wall to prevent damage.
Notice: Ensure that the clutch hydraulic hoses are positioned away from nearby vehicle components or vehicle damage may result.
1. Install the transmission to the J 42055, if removed.
2. SLOWLY slide the differential to the transmission.
Notice: Refer to Fastener Notice in Service Precautions.
3. Install the differential to transmission bolts and nuts.
^ Tighten the differential to transmission bolts and nuts to 50 Nm (37 ft. lbs.).
4. Install the transmission shift rod to the transmission shift shaft.
5. Using a drift or punch, install the roll pin (1) to retain the transmission shift rod to the shift shaft.
6. Slowly slide the driveline support assembly to the transmission, while guiding the transmission shift rod through the opening in the driveline support assembly.
7. Install the transmission to driveline support assembly bolts/studs.
^ Tighten the transmission to driveline support assembly bolts/studs to 50 Nm (37 ft. lbs.).
8. Loosely install a rubber band onto the transmission shift rod and position just behind the shift rod clamp.
(The rubber band will be used to aid in installing the shift control assembly after the driveline has been installed.)
9. Using a piece of masking tape, or similar tape which can be easily broken, affix the transmission shift rod to the driveline support assembly and position the rod just to the outside of the mounting boss used for the shift control.
(The tape is intended to keep the shift rod in position to aid in shift control installation after the driveline has been installed.)
10. Position the chainfall, or equivalent, of a lift device in a way which will protect 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.
11. Using the lift device, raise the driveline off the workbench and position the driveline with the J 42055 onto a transmission jack.
12. Connect the J 42055 to the transmission jack.
13. Remove the lift device from the driveline.
14. Position the driveline under the vehicle.
15. Begin to raise the driveline at the approximate angle used during removal.
16. Position the wiring harness-along the driveline support assembly and LOOSELY install the harness into the harness retaining slots.
17. 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.
18. Have an assistant begin to insert the propeller input shaft into the clutch driven plate 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.
19. Insert a putty knife, or similar tool, between the edge of the shifter bracket on the side of the driveline support assembly and the brake pipe retainer on the wall of the driveline tunnel.
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. Connect the transmission fluid temperature sensor electrical connector, if equipped.
26. Connect the gear select (skip shift) solenoid electrical connector.
27. Connect the reverse lockout solenoid electrical connector.
28. Connect the backup lamp switch electrical connector.
29. Connect the wiring harness clip to the top of the differential.
30. Connect the wiring harness retainer to the stud at the differential rear cover.
31. Connect the Vehicle Speed Sensor (VSS) electrical connector.
32. Slowly raise the driveline to final installation height.
33. Remove the putty knife, if still in position.
34. Remove the jack which supported the rear of 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 with 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 46 through 50 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.
Important: DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.
55. Connect the clutch actuator cylinder hose to the clutch master cylinder hose.
Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.
56. Check the clutch hydraulic hoses for twists or kinks.
57. Install the clutch actuator cylinder hose to the hose retaining clip (at the rear of the engine).
58. Install the driveline tunnel closeout panel.
59. Remove the tie-off retainers from the muffler assemblies.
60. Install the catalytic converter.
61. Install the rear tire and wheel assemblies.
62. Lower the vehicle.
63. Connect the clutch master cylinder pushrod to the clutch pedal.
64. Install the clutch master cylinder pushrod retainer.
65. Install the left IP lower insulator panel.
66. Grasp the transmission shift rod and pull up to break the masking tape installed earlier to maintain position during installation.
67. Stretch the rubber band, while still installed onto the transmission shift rod, over the rear stud on top of the driveline tunnel to aid in shift control installation.
68. Install the shift control assembly.
69. Break and remove the rubber band.
70. Install the shift control closeout boot.
Check that the closeout boot fully seats to the shift control lever seal and the base of the shift control assembly (1).
71. Install the shift control closeout boot retaining nuts.
^ Tighten the shift control closeout boot retaining nuts to 12 Nm (106 inch lbs.).
72. Install the IP accessory trim plate.
73. Install the shift control boot over the shift control lever.
74. Align the shift control boot to the IP accessory trim plate opening, then press to lock the boot retaining tabs.
75. Adjust the shape of the boot for appearance, if necessary.
76. Screw the shift control knob onto the shift control lever until the knob bottoms out.
77. Unscrew the shift control knob just enough to align the retainer slot with the slot on the shift control lever.
78. Install the shift control knob retainer (1) into the slots and seat fully.
79. Install the shift control knob button.
80. Install the console.
81. Connect the negative battery cable.
^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).
82. Program the transmitters.
83. Bleed the clutch hydraulic system.