DRIVE TRAIN

Drive Train

Transmission Assembly

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. On automatic transmission vehicles, drain the automatic transmission fluid and the front differential.
3. Remove or disconnect the following:
   • Negative battery cable
   • Air intake and chamber, then the chamber stays
   • Air cleaner case stay
   • Front and rear Oxygen (O2S) sensor connectors, if equipped
   • Transmission harness connector, if equipped with an automatic transmission
   • Transmission ground terminal
   • Neutral position switch connector, if equipped with a manual transmission
   • Backup light switch connector, if equipped with a manual transmission
   • 2 Vehicle Speed (VSS) sensor connectors
   • Starter
   • Pitching stopper
4. On automatic transmission vehicles, remove the timing hole inspection plug. Matchmark the torque converter-to-driveplate and remove the 4 bolts which hold torque converter to driveplate.
5. Remove or disconnect the following:
   • Automatic transmission fluid dipstick and tube
   • Clutch slave cylinder, on manual transmission vehicles
6. Install Engine Support Assembly ST 41099AA020. (Also available as part no. 927670000).
7. Remove or disconnect the following:
   • Bolt securing the right upper side of the transmission to the engine
   • Engine undercover
   • Front Y-pipe
8. Disconnect connector from rear O2S sensor
9. Remove or disconnect the following:
   • Center exhaust pipe from rear pipe and hanger bolt
   • Rear exhaust pipe and heat shield cover
   • Hanger bracket from the right side of the transmission
   • Transmission cooler lines
   • Rear driveshaft, matchmark for reassembly
   • Center bearing bracket

   NOTE: Plug the opening at the rear of the extension housing to prevent oil from flowing out.

10. Shifter stay and rod from the transmission, on manual transmission
11. Gear shift cable from the transmission select lever, on automatic transmission
12. Swaybar from the transverse link
13. Parking brake cable bracket from the transverse link and bolt holding the transverse link to the crossmember on each side, lower the transverse link
14. Lower ball joint from knuckle
15. Spring pin and separate the halfshaft from the transmission on each side

    NOTE: Use a small punch to remove the spring pin. Discard old spring pin and always install a new pin.

16. Disconnect the halfshaft from transmission on each side. Be sure to remove the axle shaft from the transmission by pushing the rear of the tire outward.
17. Remove the engine-to-transmission mounting nuts
18. Support the transmission with a jack.

    NOTE: Do not place jack under the transmission oil pan, otherwise the oil pan may be damaged.

19. Remove or disconnect the following:
    • Rear transmission crossmember
    • Transmission

    To install:

20. Install or connect the following:
    • Special tool 498277200 to torque converter clutch case
    • Transmission to the engine
    • Transmission crossmember. Torque the front nuts/bolts to 51 ft. lbs. (69 Nm) and the rear nuts to 101 ft. lbs. (137 Nm), on manual transmissions
    • Transmission crossmember. Torque the inner nuts/bolts to 25 ft. lbs. (34 Nm) and the rear nuts to 51 ft. lbs. (69 Nm), on automatic transmissions

      Fig. 1: Exploded view of the manual transmission mounting

      Fig. 2: Exploded view of the automatic transmission mounting

21. Remove the transmission jack.
22. Install or connect the following:
    • Transmission-to-engine mounting nuts. Torque the nuts/bolts to 37 ft. lbs. (50 Nm).
    • Torque converter-to-driveplate bolts on automatic transmission vehicles. Torque the bolts to 18 ft. lbs. (25 Nm).
    • Clutch slave cylinder on manual transmission vehicles. Torque the mounting bolts to 27 ft. lbs. (37 Nm).
23. Remove special tool 927670000.
24. Install or connect the following:
    • Pitching stopper
    • Halfshaft to transmission and spring pin into place

    NOTE: Always use new spring pin. Be sure to align the axle shaft and shaft from the transmission at chamfered holes and install shaft splines correctly.

    • Lower ball joint to knuckle
    • Sway bar to the crossmember. Torque the clamp bolts to 18 ft. lbs. (25 Nm).
    • Shift control rod, shifter stay to the transmission and the spring, on manual transmission vehicles
    • Gear shift cable to the select lever, on automatic transmission vehicles
    • Fluid cooler lines
    • Driveshaft. Tighten the bolts to 23 ft. lbs. (31 Nm).
    • Center bearing bracket. Torque the bolt to 38 ft. lbs. (52 Nm).
    • Heat shield cover, if removed
    • Center exhaust pipe from rear pipe and hanger bolt
    • Rear exhaust pipe and heat shield cover
    • Hanger bracket from the right side of the transmission
    • Y-pipe with new gaskets and nuts
    • Rear O2S sensor connector
    • Automatic transmission fluid dipstick tube
    • Transmission connector bracket
    • Starter. Torque the mounting bolts to 37 ft. lbs. (50 Nm).
    • Front and rear O2S sensor connectors
    • Transmission harness connector, on automatic transmission vehicles
    • Transmission ground terminal
    • Neutral position switch connector, on manual transmission vehicles
    • Backup light switch connector, on manual transmission vehicles
    • 2 VSS connectors
    • Air intake and chamber, and the camber stays
    • Negative battery cable
25. On automatic transmission vehicles, fill the automatic transmission fluid with Dexron® II or III or equivalent.
26. On manual transmission vehicles, check and fill the transmission with 75W-90 gear oil.
27. Road test the vehicle.