Transmission Replacement

Transmission Replacement

^ Tools Required
- J 42371 Hydraulic Clutch Line Separator

Removal Procedure





1. Shift the transmission into 3rd or 4th gear.
2. Remove the shift lever assembly.
3. Drain the transmission fluid.
4. If vehicle is a 2 wheel drive (2WD), remove the propeller shaft.
5. If vehicle is a 4 wheel drive (4WD), remove the transfer case.
6. Using J 42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the clutch actuator quick connect.





7. Disconnect the following engine wiring harness electrical connectors:
^ No Vehicle speed sensor (VSS) (1)
^ Backup lamp switch (3)
^ Oxygen sensor (4)
8. Remove the engine harness clips from the fuel feed/return line clips and transmission.
9. If equipped with 4WD, remove the clamp securing the harness to the fuel feed/return pipe bracket.





10. If equipped with 4WD, remove the vent hose clip from the bracket.





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





12. If equipped with 4WD, remove the fuel feed/return hose clip from the bracket.
13. Remove the starter motor.





14. If equipped with the 4.3L engine, remove the transmission cover bolts.
15. Support the transmission using a suitable transmission jack.
16. Remove the transmission support crossmember.





17. Remove the bolts securing the bottom right side of the transmission to the engine. Bolt (1) secures the transmission cover on 4.3L engine only.
18. Remove the transmission cover.





19. Remove the stud securing the right side of the transmission to the engine.





20. Remove the transfer case vent hose clip bracket nut and bracket.On the 4.3L engine this bracket is located at the 1 o'clock position and on the 4.8L engine this bracket is located at the 12 o'clock position.





21. Remove the bolt and studs securing the transmission to the engine.
22. Pull the transmission straight back off the clutch hub splines. Do not let the transmission hang from the clutch assembly.
23. Remove the transmission from the vehicle.

Installation Procedure





1. Notice: Refer to Fastener Notice in Service Precautions.

Install the transmission to the vehicle:
1. Ensure the transmission is positioned in the 3rd or 4th gear.
2. Rotate the transmission clockwise onto the clutch hub splines.
3. Install the bolt and studs securing the transmission to the engine.
^ Tighten the bolt/studs to 50 Nm (37 ft. lbs.).





2. Install the transfer case vent hose clip bracket and nut.On the 4.3L engine this bracket is located at the 1 o'clock position and on the 4.8L engine this bracket is located at the 12 o'clock position.





3. Install the stud securing the right side of the transmission to the engine.
^ Tighten the stud to 50 Nm (37 ft. lbs.).





4. Install the transmission cover.
5. Install the bolts securing the bottom right side of the transmission to the engine. Bolt (1) secures the transmission cover on the 4.3L engine only.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
6. Install the transmission support crossmember.
7. Remove the transmission jack.





8. If equipped with the 4.3L engine, install the transmission cover bolts.
^ Tighten the bolts to 9 Nm (80 inch lbs.).
9. Install the starter motor.





10. If equipped with 4WD, install the fuel feed/return hose clip to the bracket.





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





12. If equipped with 4WD, install the vent hose clip to the bracket.





13. If equipped with 4WD, install the clamp securing the harness to the fuel feed/return pipe bracket.
14. Install the engine harness clips to the fuel feed/return line clips and transmission.
15. Connect the following engine harness electrical connectors:
^ VSS (1)
^ Backup lamp switch (3)
^ Oxygen sensor (4)





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

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 kinks or twists.
19. If vehicle is a 4WD, install the transfer case.
20. If vehicle is a 2WD, install the propeller shaft.
21. Fill the transmission with fluid.
22. Install the shift lever assembly.
23. Bleed the clutch hydraulic system.