Gearbox Converter And Transfer Gearbox Assembly
The content of this article/image reflects the changes identified in TSBBulletin No.: TEC440106 Dated 6/13/2006
Gearbox & Converter And Transfer Gearbox Assembly - Remove For Access And Refit
44.20.04.99
Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.
NOTE: When transmission is removed for access only, the transmission oil is not drained
Remove
1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove air intake plenum.
4. Disconnect multiplug from inhibitor switch harness.
5. Release clips securing LH oxygen sensor lead from gearbox bell housing.
6. Remove 2 Torx bolts from top of bell housing.
7. Raise vehicle on fill.
8. Remove exhaust system.
19. Remove the three transmission heat shields.
11. Remove eight hexagonal headed screws securing fuel tank heat shield and remove heat shield.
11. Referance mark rear driveshaft for reassembly.
12. Remove six torx bolts securing driveshaft to transfer box flange.
13. Release driveshaft, and tie aside.
14. remove front driveshaft.
15. Using LRT-44-032 support gearbox on jack, arrow in graphic points towards front of vehicle.
16. Remove nut and bolt securing mounting to cross member.
17. Remove 6 bolts securing cross member and remove cross member.
18. Remove snubbers from mounting.
19. Lower gearbox on jack.
CAUTION: Do not allow gearbox to hang on gear selector cable.
20. Disconnect multiplug from high/low shift motor.
21. Disconnect multiplug from gearbox housing.
22. Release clips securing oxygen sensor leads to transfer gearbox.
23. Remove nut securing selector lever to gearbox selector shaft and release lever.
24. Remove 2 bolts securing selector cable support bracket to gearbox and tie cable aside.
25. Remove bolt securing crankshaft sensor, remove sensor and position aside.
26. Release RH oxygen sensor harness from gearbox casing.
27. Remove undertray.
28. Remove grommet from bell housing to gain access to torque converter retaining bolts.
29. Rotate crankshaft for access and remove 4 bolts securing drive plate to torque converter.
30. Remove 2 bolts securing starter motor and tie aside.
31. Remove bolt securing fluid cooler saddle clamp to sump.
32. Remove banjo bolt securing fluid cooler pipe to LH side of gearbox and discard sealing washers.
33. Release fluid cooler pipe from RH side of gearbox and discard "O" ring.
32. Remove 8 Torx bolts from bell housing.
34. With assistance, carefully remove gearbox from engine. Ensure torque converter remains with gearbox.
35. Fit convener retaining plate and secure with bolts.
Refit
1. Clean mounting and mating faces.
2. Remove torque convener retaining plate.
3. With assistance,carefully tit gearbox to engine. Ensure engagement of torque convener spigot and gearbox housing onto dowels.
4. Fit 8 Torx bolts securing automatic gearbox to engine, tighten to 45 Nm (33 ft. lbs.)
5. Clean fluid cooler pipes unions and mating faces.
6. Position fluid cooler pipe to LH side of gearbox.
7. Lubricate fluid cooler sealing washers with transmission fluid, fit banjo bolt to gearbox and tighten to 37 Nm (27 ft. lbs.)
8. Fit and lubricate new "O" ring to fluid cooler pipe, fit pipe to gearbox and tighten to 37 Nm (27 ft. lbs.).
9. Position fluid cooler saddle clamp, fit bolt and tighten to 6 Nm (4.4 ft. lbs.)
10. Fit starter motor and tighten bolts to 45 Nm (33 ft. lbs.).
11. Fit bolts securing drive plate to torque converter and tighten to 45 Nm (33 ft. lbs.)
12. Fit grommet to gearbox bell housing.
13. Fit undertray.
14. Fit oxygen sensor leads to gearbox casing.
15. Clean crankshaft sensor and mating face.
16. Position crankshaft sensor, tit bolt and tighten to 6 Nm (4.4 ft. lbs.)
17. Position selector cable support bracket to gearbox, fit bolts and tighten to 10 Nm (7 ft. lbs.)
18. Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 ft. lbs.)
19. Fit and secure oxygen sensor leads to transfer gearbox.
20. Connect multiplug to gearbox connector.
21. Connect multiplug to high/low shift motor.
22. Raise gearbox on jack.
23. Fit snubbers.
24. Fit cross member to mounting, fit nut and bolt but do not tighten at this stage.
25. Align cross member, fit bolts and tighten to 68 Nm (50 ft. lbs.).
26. Remove support from gear box.
27. Tighten nut and bolt securing mounting to cross member to 100 Nm (74 ft. lbs.).
28. Fit heat shield and secure with nuts.
29. Fit rear propeller shaft.
30. Fit front propeller shaft.
31. Lower vehicle.
32. Fit top bell housing Torx bolts and tighten to 25 Nm (18 ft. lbs.)
33. Fit and secure LH oxygen sensor lead to gearbox bell housing.
34. Connect inhibitor switch multiplug.
35. Fit air intake plenum.
36. Fit fan to pulley and tighten viscous coupling nut to 40 Nm (30 ft. lbs.).
37. Connect batted earth lead.
38. Fill gearbox with fluid.