Removal

Special Tools:

REMOVAL





1. Place the transmission range selector lever in the NEUTRAL position.
2. If equipped, turn the air suspension switch OFF.
3. Disconnect the battery ground cable.
4. Raise the vehicle on a hoist.
5. If transmission disassembly is required, drain the transmission fluid.





6. Remove the transmission oil filler tube.
1 Remove the bolt.
2 Remove the oil filler tube.





7. Position a suitable drain pan and disconnect the transmission fluid cooler tubes at the Cooler Bypass Valve (CBV).
8. On 4x4 equipped vehicles; remove the transfer case assembly.





9. Remove the rear driveshaft.
1 Remove the four bolts.
2 Lower the driveshaft and slide the driveshaft rearward out of the extension housing.
^ Install an appropriate plug in the transmission to prevent fluid leakage.

NOTE: To maintain driveshaft balance, mark the driveshaft yoke and axle flange so they may be installed in their original position.





10. Disconnect the shift cable from the transmission.
1 Disconnect the shift cable from the manual lever.
2 Disconnect the cable housing from the bracket and position aside.





11. Disconnect the connector.





12. Disconnect connector.





13. Disconnect the connector.
14. Remove the starter motor.





15. Remove the cylinder block opening cover.





16. Disconnect the torque converter.
^ Rotate the crankshaft to position the torque converter-to-flywheel nut in the center of the cylinder block opening.
^ Remove and discard the torque converter-to-flywheel nuts.





17. Remove the flywheel inspection cover.
1 Remove the bolts.
2 Remove the inspection plate.





18. Remove the bolts.





19. Using the Hi-Lift Jack and the Hi-Lift Jack Adapter attach the E40D Transmission to the Hi-Lift Jack.

CAUTION: Make sure any securing straps or the E40D transmission jack adapter do not touch the Cooler Bypass Valve (CBV). Do not use the CBV as a handle. Damage to the CBV may cause a leak and/or failure to the transmission assembly.

20. Remove the exhaust and crossmember.





21. Remove the transmission.
1 Remove the six transmission to engine mounting bolts.
2 Gently rock the transmission side-to-side to disengage it from the locator dowels.
3 Move the transmission and the transmission jack rearward to clear the engine flywheel.

22. Install Torque Converter Holding Tool.





23. Wiggle the transmission back and forth and lower the transmission out of the vehicle.

CAUTION: Use care while removing the transmission to avoid obstructions. Do not use the CBV as a handle. Damage to the CBV assembly may occur or damage to the case may result. If a safety strap is being used to hold the transmission to the High-Lift Transmission Jack, place the strap behind the CBV to prevent damage to the CBV.

24. Remove Torque Converter Holding Tool.





25. If required, remove the torque converter from the transmission.
1 Install the Torque Converter Handles and position them at 6 o'clock and 12 o'clock.
2 Carefully remove the (A) torque converter from the (B) transmission by pulling evenly on the handles.

WARNING: THE TORQUE CONVERTER IS VERY HEAVY.

NOTE: Fluid loss will occur when the torque converter is removed.