Transmission Replacement

Transmission Replacement

Removal Procedure





1. Shift the transmission into 3rd or 4th gear.
2. Remove the shift lever.
3. Raise and suitably support the vehicle. Refer to Vehicle.

Important: The clutch actuator cylinder hose can remain attached to the clutch actuator. Disconnecting the hose from the clutch actuator cylinder will cause the fluid to drain from the hydraulic system.

4. Drain the transmission fluid.
5. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft.
6. If equipped with 4 wheel drive (4WD), remove the transfer case.
7. Disconnect the clutch actuator cylinder hydraulic hose quick connect at the master cylinder.
8. Disconnect the clutch actuator cylinder line retaining clips.





9. If equipped with a 6.6L engine, disconnect the following electrical connectors:
^ Power take-off (PTO) (2), if connected
^ Backup lamp switch (3)
^ Vehicle speed sensor (VSS) (4)
10. Remove the engine harness clips (1) from the fuel feed/return brackets.
11. Remove the PTO connector from the fuel feed/return bracket.
12. Reposition the harness.
13. Remove the fuel lines from the fuel feed/return brackets.





14. If equipped with a 8.1L engine, disconnect the following electrical connectors:
^ Power take-off (PTO) (2), if connected
^ Oxygen sensors (1, 3)
^ Backup lamp switch (4)
^ VSS (5)
15. Remove the engine harness clips (6) from the fuel feed/return brackets.
16. Remove the PTO connector from the fuel feed/return bracket.
17. Remove the oxygen sensors connectors (1, 3) from the fuel feed/return hose clip and transmission bracket.
18. Reposition the harness.
19. Remove the fuel lines from the fuel feed/return brackets.





20. If equipped with 4WD, remove the vent hose clip from the bracket.
21. Remove the vent hose clip nut and clip.





22. If equipped with 4WD, remove the vent hose clip (1) from the fuel feed/return bracket.
23. Remove the starter.



24. Remove the exhaust pipe hanger bracket bolts and bracket.
25. Support the transmission with a suitable transmission jack.
26. Remove the transmission support.





27. If equipped with a 6.6L engine, remove the transmission bolts/studs.
28. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
29. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
30. Remove the insulator from the top of the transmission.





31. If equipped with a 8.1L engine, remove the transmission studs.
32. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
33. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
34. Remove the insulator from the top of the transmission.

Installation Procedure





1. Install the insulator to the top of the transmission.
2. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
3. Rotate the transmission clockwise onto the clutch hub splines.
4. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.

Notice: Refer to Fastener Notice in Service Precautions.

5. If equipped with a 8.1L engine, install the transmission studs.
^ Tighten the studs to 50 Nm (37 ft. lbs.).





6. Install the insulator to the top of the transmission.
7. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
8. Rotate the transmission clockwise onto the clutch hub splines.
9. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
10. If equipped with a 6.6L engine, install the transmission bolts/studs.
^ Tighten the bolts/studs to 50 Nm (37 ft. lbs.).
11. Install the transmission support.
12. Remove the transmission jack.





13. Install the exhaust pipe hanger bracket and bolts.
^ Tighten the bolts to 12 Nm (106 inch lbs.).
14. Install the starter.





15. If equipped with 4WD, install the vent hose clip (1) to the fuel feed/return bracket.





16. Install the vent hose clip and nut.
^ Tighten the nut to 25 Nm (18 ft. lbs.).
17. If equipped with 4WD, install the vent hose clip to the bracket.





18. Install the fuel lines to the fuel feed/return brackets.
19. Position the harness.
20. Install the oxygen sensors connectors (1, 3) to the fuel feed/return hose clip and transmission bracket.
21. Install the PTO connector to the fuel feed/return bracket.
22. Install the engine harness clips (6) to the fuel feed/return brackets.
23. If equipped with a 8.1L engine, connect the following electrical connectors:
^ PTO (2), if connected
^ Oxygen sensors (1, 3)
^ Backup lamp switch (4)
^ VSS (5)





24. Install the fuel lines to the fuel feed/return brackets.
25. Position the harness.
26. Install the PTO connector to the fuel feed/return bracket.
27. Install the engine harness clips (1) to the fuel feed/return brackets.
28. If equipped with a 6.6L engine, connect the following electrical connectors:
^ PTO (2), if connected
^ Backup lamp switch (3)
^ VSS (4)





29. Connect the clutch actuator cylinder line retaining clips.

Important: Improper connection may cause the quick connect from locking properly. Before pushing in the clutch pedal fully, check with light pressure. If pedal is hard recheck the connection.

30. Connect the clutch actuator cylinder hydraulic hose quick connect from the master cylinder.
31. If equipped with 4WD, install the transfer case.
32. If vehicle is a 2WD, install the rear propeller shaft.
33. Lower the vehicle.
34. Install the shift lever.
35. Fill the transmission with fluid.
36. Bleed the clutch hydraulic system, if necessary.