Removal and Installation
Transmission
Removal
1. Place the gears shift selector in the neutral (N) position.
2. Remove the boot retainer screws and the boot. Remove the bolts attaching the gear shift lever assembly to the control housing.
3. Pull the gearshift lever assembly out of the control housing.
4. Cover the opening in the control housing with a cloth to prevent dirt from falling into the transmission.
5. Open the hood and disconnect the negative battery cable from the battery terminal.
6. Raise the vehicle.
7. Disconnect the rear driveshaft at both the rear axle and transfer case flanges.
8. Disconnect the forward drive shaft from the front axle and remove by sliding forward. Install a suitable plug in the transfer case adapter to prevent lubricant leakage.
9. Disconnect the hydraulic fluid line from the clutch slave cylinder. Plug the line to prevent fluid leakage.
10. Disconnect the speedometer from the transfer case.
11. Disconnect the starter motor cable, the backup lamp switch wire, and the neutral position switch wire.
12. Place a jack under the engine block, protecting the oil pan with a wood block.
13. Remove the transfer case from the vehicle
14. Remove the starter. Place a transmission jack under the transmission.
15. Remove the bolts, lockwashers and flat washers attaching the clutch housing and transmission to the engine and plate.
16. Remove the nuts and bolts attaching the transmission mount and damper to the crossmember.
17. Remove the nuts and bolts attaching the crossmember to the frame side rails and remove the crossmember.
18. Lower the engine jack. Work the clutch housing off the locating dowels and slide the clutch housing and the transmission rearward until the input shaft clears the clutch disc. Remove the transmission from the vehicle.
19. Remove the clutch housing from the transmission.
Installation
1. Make sure that the machined mating surfaces and the locating dowels on the engine rear plate are free of burrs, dirt or paint. Check the mating face of the clutch housing and the locating dowel holes for burrs, dirt or paint. Reassemble clutch housing to the transmission.
2. Mount the clutch housing and transmission on a transmission jack. Position it under the vehicle and start the input shaft into the clutch disc. Align the splines on the input shaft with the splines in the clutch disc. Move the transmission forward and carefully seat the clutch housing on the locating dowels of the engine rear plate. The engine plate dowels must not shave or burr the clutch housing dowel holes.
3. Install the bolts and flatwashers that attach the clutch housing to the engine rear plate and tighten to specifications. Remove the transmission jack. Specifications
4. Install the starter motor. Tighten the attaching nuts to specifications. Specifications
5. Raise the engine and install the rear crossmember, insulator and damper and attaching nuts and bolts. Tighten the nuts to specifications. Specifications
6. Install the bolts, nuts and washers attaching the transmission mount to the crossmember. Tighten the nuts to specifications. Remove the engine jack. Specifications
7. Install the transfer case as described in the appropriate section in this group.
8. Install the rear driveshaft by attaching to both the transfer case and the rear axle flange. Make sure the marks made during removal are in alignment. Install the attaching nuts and bolts and tighten to specifications. Drive Axles, Bearings and Joints
9. Install the forward driveshaft by sliding it rearward into the transfer case and attaching it to the forward drive axle. Make sure the marks made during removal are in alignment. Install the attaching nuts and bolts and tighten to specifications.
10. Connect the starter cable, backup lamp switch wire, shift indicator wire and the neutral position switch wire (if so equipped).
11. Connect the clutch hydraulic line to slave cylinder on the input shaft. Bleed the hydraulic clutch system. Clutch Hydraulic System
12. Install the speedometer cable
13. Remove the fill plug and check the fluid level. The fluid level should be even with the bottom of the filler hole. If required, fill to the specified level with Standard Transmission Lubricant (SAE 80W), D8DZ-1 9C547-A (ESP-M2C83-C) or equivalent.
14. Lower the vehicle.
15. Connect the negative battery cable to the battery terminal.
16. Remove the cloth over the transfer case adapter opening. Avoid getting dirt in the adapter.
17. Install the gearshift lever assembly in the control housing. Make sure the ball on the lever is in the socket inside the transmission. Install the attaching bolts and tighten to specifications.
18. Install the boot cover and bolts.
19. Verify proper shifting and operation of the transmission.
Shift Lever
NOTE: Remove only the shift ball it the shift ball, boot or lever is to be replaced. If either the ball, boot or lever is not being replaced, remove the ball, boot and lever as an assembly.
Removal
1. Pull the shift boot down below the retaining ring on the shift lever and remove the shift ball as follows: Warm the ball with a heat gun to 60-82°C (140-180°F). Knock the ball off the lever with a "U" shaped tool.
2. Remove the boot retainer screws and the boot bezel assembly.
3. Remove the bolts retaining the shift lever to the control housing and remove the lever assembly.
Installation
1. Lubricate the shift lever selector ball with Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent. Position the lever in the control housing, making sure the selector ball is in the socket. Install the bolts and tighten to 8-14 N m (6-10 ft-lb).
2. Install the boot and bezel assembly.
3. Warm the ball with a heat gun to 60-82°C (140-180°F) and tap the ball on the lever with a 7/16 inch socket and mallet. Install the plastic shift pattern insert. Use caution to align the insert properly.
1. Disconnect battery ground cable (both battery ground cables on diesel engine).
2. Place gearshift lever in neutral position, then remove boot retainer screws.
3. Remove retainer cover to gearshift lever retainer attaching bolts, then disconnect clutch master cylinder pushrod from clutch pedal.
4. Pull gearshift lever assembly, shim and bushing straight up away from the gearshift lever retainer.
5. To avoid dirt entering shift tower opening in extension housing, cover with cloth.
6. Disconnect clutch hydraulic system master cylinder pushrod from clutch pedal.
7. Raise and support vehicle.
8. Disconnect driveshaft at rear axle drive flange then pull driveshaft rearward and disconnect from transmission. Install suitable plug in extension housing to prevent lubricant leakage.
9. Remove clutch housing dust shield and slave cylinder and secure to the side.
10. Disconnect starter motor and back-up lamp switch wires.
11. Place suitable jack under engine using a block of wood between jack and engine to protect the oil pan.
12. Remove speedometer cable from extension housing.
13. On four-wheel drive vehicles, remove the transfer case.
14. On all models, remove starter motor and position a transmission jack under transmission.
15. Remove bolts, lockwasher and flat washer attaching transmission to the engine rear plate.
16. Remove nuts and bolts attaching transmission mount to crossmember.
17. Remove nuts attaching crossmember to frame side rails and remove crossmember.
18. Lower the jack then work clutch housing from locating dowels and slide transmission rearward until input shaft spline clears clutch disc.
19. Remove transmission from vehicle.
20. Reverse procedure to install.