Manual Transmission/Transaxle: Service and Repair

Exploded View Of 5 Speed Manual Transmission:

1. Disconnect battery ground cable.
2. Remove air cleaner and the starter motor.
3. Remove upper transmission attaching bolts from bellhousing.
4. Working from inside vehicle, remove lock screws, then lift console box upward and remove it. If vehicle does not have a console, lift carpet upward over center tunnel.
5. Remove lock screws, then lift dust cover retaining plate upward and remove it.
6. Turning dust cover upward, remove four attaching bolts at lower part of extension housing and remove gearshift lever assembly. Remove gearshift lever with lever placed in second speed on four speed transmission models or first speed on five speed transmission models.
7. Raise and support vehicle, then drain transmission fluid.
8. Remove speedometer cable, then disconnect transmission switch and back-up light switch wiring from transmission.
9. Remove bolts from rear propeller shaft, then withdraw propeller shaft from transmission.
10. On 4 wheel drive models, remove transfer plate skid plate, then the front propeller shaft.
11. On all models, disconnect front exhaust pipe.
12. Disconnect clutch cables on gasoline engine models. On diesel engine models, remove clutch release cylinder. Support rear of engine with jack. On four wheel drive models, remove transfer case mounting bracket.
13. With transmission supported on a transmission jack, remove No. 2 crossmember.
14. Remove bellhousing cover.
15. Remove retaining bolts from transmission and draw transmission rearward from engine. Be careful not to twist front end of the main drive gear.
16. Reverse procedure to install, noting the following:
a. When installing control lever assembly, place shift lever in second speed position on four speed transmission models or in first speed position on five speed transmission models, so that nylon bushing hole is vertical. During this operation, use care to prevent dirt from entering transmission at control housing mounting section.
b. When assembling bellhousing cover, ensure cover is not bent. A bent cover will not make proper contact with cylinder block and transmission, resulting in entry of mud into transmission.
c. Install gearshift lever dust cover snugly into hole in tunnel and attach retaining plate with screws.
d. Adjust clutch pedal as described under "Clutch Pedal, Adjust."
e. Fill transmission with specified amount of fluid.