Manual Control Lever Shaft and Seal

Manual Control Lever Shaft and Seal









Removal

NOTICE: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will affect the operation of the transmission.

Use of a transmission fluid other than specified could result in transmission failure.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

Four-Wheel Drive (4WD) vehicles

2. Remove the front driveshaft shield nuts and remove the shield.





3. NOTE: It is not necessary to remove the front driveshaft from the vehicle.

Index-mark the front driveshaft flange to the pinion flange and rear driveshaft flange to the transfer case flange. Disconnect the front driveshaft and position aside.





All vehicles

4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.

Remove the selector lever cable end from the manual control lever.





5. Disconnect the Transmission Range (TR) sensor connector.





6. NOTE: Discard the manual control lever shaft outer nut. Do not reuse. The old nut will not retain the proper torque specification.

Remove the manual control lever.

1. Remove and discard the manual control lever outer nut.

2. Remove the manual control lever.





7. Remove the TR sensor bolts and the TR sensor.





8. Loosen, but do not remove the transmission fluid pan bolts and allow the transmission fluid to drain. Once the transmission fluid has drained, remove the bolts. Remove the transmission fluid pan and gasket.





9. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and the magnet.





10. Remove the manual control valve detent lever bolt and spring.





11. NOTE: When removing the manual control lever shaft retaining pin, use a soft cloth to protect the surface of the case.

Remove the manual control lever shaft retaining pin.





12. NOTICE: Use care not to damage the manual control lever shaft bore. The new seal can leak.

Remove the inner manual control lever shaft inner nut and slide the manual control lever shaft out of the case.





13. If required, remove the park lever actuating rod assembly.

1. Remove the manual valve detent lever.

2. Remove the park lever actuating rod.





14. Remove the manual control lever shaft seal.





Installation

All vehicles

1. Using the Shift Shaft Fluid Seal Installer, install the manual control lever shaft seal.





2. If required, install the park lever actuating rod assembly.

1. Install the park lever actuating rod.

2. Install the manual valve detent lever.





3. Install the manual control lever shaft.

1. Install the manual control lever shaft.

2. Install the inner manual control lever shaft inner nut.
- Tighten to 31 Nm (23 lb-ft).

3. Install the manual valve control lever shaft retaining pin.





4. Install the manual control valve detent lever spring and bolt.
- Tighten to 10 Nm (89 lb-in).





5. Position the pan magnet into the transmission fluid pan.





6. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the transmission fluid pan gasket should be reused.

Install the transmission fluid pan and gasket.

1. Position the transmission fluid pan and gasket.

2. Install the transmission fluid pan bolts.
- Tighten to 14 Nm (124 lb-in).





7. Install the TR sensor and loosely install the bolts.





8. NOTE: The manual control lever must be in the NEUTRAL position.

Using the TR Sensor Alignment Gauge, align the TR sensor slots. The tool is designed to fit snugly.





9. NOTICE: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged.

Tighten the bolts in an alternating sequence.

- Tighten to 9 Nm (80 lb-in).





10. Install the manual control lever.

1. Position the manual control lever.

2. Install a new manual control lever outer nut.
- Tighten to 33 Nm (24 lb-ft).





11. Connect the TR sensor connector.





12. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.

NOTE: When installing the selector lever cable onto manual control lever, pull back on the selector lever cable end and make sure that the selector lever cable end is correctly installed onto the manual control lever.

Install the selector lever cable end onto the manual control lever with the lever in the (D) position.





4WD vehicles

13. Install the front driveshaft and align the index marks made during removal. Install the bolts.
- Tighten to 55 Nm (41 lb-ft).





14. Install the front driveshaft shield and install the 2 nuts.
- Tighten to 18 Nm (159 lb-in).





All vehicles

15. NOTE: When filling the transmission, start with a minimum of 4.7L (5 qt).

Fill the transmission to the correct level, using approved transmission fluid.

- Verify for correct operation.

- Check for leaks.