Borg Warner T5R Transmission

DISASSEMBLED VIEW

REMOVAL
1. Disconnect battery ground cable.
2. Remove gear control lever knob (1) and place gear shift lever in the neutral position.





3. Remove lower cluster assembly (2).





4. Remove rear console (3).





5. Remove center console (4).





6. Remove grommet assembly (5).





7. Remove gear control lever (6).





8. Raise and support vehicle with suitable jack stands. Remove flexible hose bracket and slave cylinder (7) with pipe.

9. Remove propeller shaft flange yoke bolts and nuts at the differential side.





NOTE: Apply alignment marks on the flange at both front and rear sides.

10. Remove propeller shaft (8) from the transmission main shaft spline.





11. Remove fuel pipe heat protector (9) and clip.
12. Disconnect reverse switch and speed sensor harness connector.
13. Remove two cover bolts from the clutch housing and flywheel under cover (10).
14. Support the transmission with a transmission jack.





15. Remove two transmission mounting rubber nuts (11).
16. Remove transmission mount rubber (12).
17. Remove six crossmember bolts and third crossmember (13).
18. Remove transmission retaining nuts and bolts. Remove the transmission (14) from the vehicle.

INSTALLATION
1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline.
2. Slowly operate the transmission jack until the front of transmission jack is aligned with rear of the engine. The slope of the engine and the transmission must be the same.
3. Align the top gear shaft spline with the clutch driven plate spline. Install the transmission (14) to the engine.





4. Tighten the transmission nuts and bolts as shown in the figure. Flexible hose bracket bolt is installed at the step of slave cylinder installation.
5. Install the transmission mounting rubber (12) to the transmission case.

Torque: 41 Nm (30 ft. lbs.)

6. Install the third crossmember (13) to the frame.

Torque: 76 Nm (56 ft. lbs.)





7. Install the transmission to third crossmember.

Torque: 41 Nm (30 Ft. lbs.)

Remove the transmission jack from transmission side.
8. Install flywheel under cover (10).
9. Connect reverse switch and speed sensor harness connector.








10. Connect fuel pipe to transmission side.





11. Install fuel pipe heat protector (9) and clip.
12. Insert propeller shaft splined yoke into the transmission mainshaft spline. Install the propeller shaft flange yoke to the drive pinion flange.

Torque: 50 Nm (37 ft. lbs.))





13. Install slave cylinder (7) and flexible hose bracket.

Slave cylinder bolt
Torque: 50 Nm (37 ft. lbs.)
Flexible hose bracket bolt
Torque: 40 Nm (30 ft. lbs.)





14. Lower the vehicle and install gear control lever (6).





15. Install grommet assembly (5).
16. Install center console (4), rear console (3) and lower. cluster assembly (2). Install gear control lever knob (1).
17. Connect battery ground cable.