Transmission Replacement

Transmission Replacement

Removal Procedure




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the positive battery post from the underhood junction block (2).
3. Disconnect the positive cables from the underhood junction block (1).
4. Disconnect the surge tank inlet hose from the surge tank.




5. Remove the underhood junction block bracket nuts (1, 2).
6. Loosen the underhood junction block bracket bolt (3).
7. Disconnect the front wiring harness from the underhood junction block bracket.




8. Reposition the underhood junction block bracket aside.




9. Disconnect the hydraulic clutch hose from the clutch actuator cylinder.
10. Install the engine support fixture. Refer to Engine Support Fixture.




11. Secure the cooling module to the upper body structure.




12. Remove the upper transmission to mount bolts.
13. Remove the upper transmission to engine bolt.
14. Remove the frame. Refer to Frame Replacement.
15. Drain the transaxle. Refer to Transmission Fluid Replacement.
16. Disconnect the drive axles from the transmission and secure out of the way. Refer to Wheel Drive Shaft Replacement.
17. Remove the starter. Refer to Starter Motor Replacement (RPO LSJ) Starter Motor Replacement (RPOs L61/LE5).




18. Disconnect the shift cables from the transmission. Refer to Shift Cable Replacement.




19. Disconnect the backup lamp switch harness connector (1).
20. Disconnect the vehicle speed sensor (2).
21. Lower the vehicle.
22. Use the engine support fixture rear hook to lower the powertrain enough to allow clearance between the side rail and powertrain.
23. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
24. Use a transmission jack to secure the transmission, and remove the transmission to engine bolts.
25. Remove the transmission from the vehicle.
26. Remove the front transmission mount from the transmission. Refer to Transmission Front Mount Replacement.
27. Remove the rear transmission mount and bracket from the transmission. Refer to Transmission Rear Mount Replacement.

Installation Procedure

1. Install the rear transmission mount to the transmission. Refer to Transmission Rear Mount Replacement.
2. Install the front transmission mount to the transmission. Refer to Transmission Front Mount Replacement.
3. Use a transmission jack to position the transmission to the vehicle.





Notice: Refer to Fastener Notice.

Important: The number 3 position does not require a bolt.

4. Secure the transmission to the engine.

Tighten the bolts to 75 N.m (55 lb ft).




5. Connect the vehicle speed sensor (2).
6. Connect the backup lamp switch harness connector (1).
7. Connect the shift cable to the transmission. Refer to Shift Cable Replacement.
8. Install the starter. Refer to Starter Motor Replacement (RPO LSJ) Starter Motor Replacement (RPOs L61/LE5).
9. Connect the drive axles to the transmission. Refer to Wheel Drive Shaft Replacement.
10. Lower the vehicle.
11. Use the engine support fixture in order to raise the powertrain assembly.
12. Install the transmission side mount. Refer to Transmission Mount Replacement - Left Side.




13. Position the underhood junction block to the original position.
14. Install the surge tank inlet hose to the surge tank.




15. Install the front wiring harness to the junction block bracket.
16. Connect the positive battery cables to the junction block bracket (1).
17. Install the positive battery post to the junction block bracket (2).




18. Install the junction block bracket, bolt (3) and nuts (1,2).

^ Tighten the nuts to 10 N.m (89 lb in).
^ Tighten the bolt to 25 N.m (18 lb ft).

19. Install the frame. Refer to Frame Replacement.
20. Remove the engine support fixture.
21. Install the top engine to transmission bolt.

Tighten the bolt to 75 N.m (55 lb ft).




22. Connect the hydraulic clutch hose to the clutch actuator cylinder.
23. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.




24. Release the cooling module from the upper body structure.
25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
26. Fill the transmission to the proper level. Refer to Transmission Fluid Replacement.