DRIVE TRAIN

Drive Train

Transmission Assembly

REMOVAL & INSTALLATION

Manual Transmission

Before servicing the vehicle, refer to the precautions in the beginning of this section.
Drain the transmission fluid.
Place the transmission in Neutral.
Remove or disconnect the following:
- Negative battery cable
- Gearshift lever assembly from the control housing
On 2WD vehicles, matchmark the driveshaft to the rear axle flange. Position a drain pan under the rear of the transmission. Remove the driveshaft-to-rear axle flange fasteners and pull the driveshaft rearward to disengage it from the transmission.
- Heated Oxygen (HO2S) sensor
- Back-up lamp switch electrical connector
- Fan shroud
- Clutch hydraulic line at the clutch housing
- Speedometer from the transfer case/extension housing and place a wood block on a service jack and position the jack under the engine oil pan
- Transfer case on 4WD vehicles
- Starter
Position a transmission jack under the transmission.
- Transmission-to-engine retaining bolts and washers
- Transmission mount and damper to the crossmember
- Crossmember and lower the engine jack slightly to angle the transmission assembly. 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
- Exhaust inlet cross over pipe
- Transmission from the vehicle
To install:
Check that the mating surfaces of the clutch housing, engine rear and dowel holes are free of burrs, dirt and paint.
Place the transmission on the transmission jack. Position the transmission under the vehicle, then raise it into position. Align the input shaft splines with the clutch disc splines and work the transmission forward onto the locating dowels.
Install or connect the following:
- Transmission-to-engine retaining bolts and washers. Tighten the retaining bolts to 30–41 ft. lbs. (40–55 Nm).
- Exhaust inlet cross over pipe and remove the transmission jack
- Right side transmission mount. Torque the bolt to 81 ft. lbs. (110 Nm).
- Rear crossmember. Torque the bolts to 53 ft. lbs. (72 Nm).
- Starter motor and tighten the attaching nuts
- Transfer case on 4WD vehicles. Torque the bolts to 87 ft. lbs. (119 Nm).
- Rear driveshaft
- Starter motor, back-up lamp switch connectors
- Hydraulic clutch line and bleed the system
- Speedometer cable
- Gearshift lever assembly
- Negative battery cable
Fill the transmission fluid to the proper level.
Check for proper shifting and operation of the transmission.

Automatic Transmission

Before servicing the vehicle, refer to the precautions in the beginning of this section.
Drain the transmission fluid.
Place the transmission in Neutral.
Remove or disconnect the following:
- Negative battery cable
- Fluid level indicator
- Fan shroud
- Transfer case on 4WD vehicles
- Rear driveshaft after matchmarking the yoke and axle flange
- Starter
- Torque converter access cover from the lower right side of the converter housing on the 3.0L engine
- Torque converter access cover from the bottom of the engine oil pan on the 2.3L and 2.5L engines
- Access cover and adapter plate bolts from the lower left side of the converter housing, on all other applications
- Flywheel-to-converter attaching nuts. Use a socket and breaker bar on the crankshaft pulley attaching bolt. Rotate the pulley clockwise as viewed from the front to gain access to each of the nuts.
NOTE: On belt-driven overhead cam engines, never rotate the pulley in a counterclockwise direction as viewed from the front.
- Shifter cable
- Transmission wire harness
- Heated Oxygen (HO2S) sensor connector
- Transmission connector
- Digital Transmission Range (TR) sensor connector
- Catalytic converter
- Speedometer cable and/or vehicle speed sensor from the transfer case (4WD) or extension housing (2WD)
- Transmission cooler lines
- Engine rear support-to-crossmember bolts and the crossmember-to-frame side support attaching nuts and bolts
- Crossmember
- Transmission mount
- Transmission upper fill tube
- Vent tube on 4WD vehicles
- Converter housing-to-engine bolts
Move the transmission to the rear so it disengages from the dowel pins and the converter is disengaged from the flywheel. Lower the transmission from the vehicle.
Remove the torque converter from the transmission, if necessary.
To install:
Install the converter on the transmission.
WARNING
Before installing an automatic transmission, always check that the torque converter is fully seated into the transmission. Typically, the converter has notches or tangs on the hub that must engage the transmission fluid pump. If they are not engaged in the pump, the transmission will not mate to the engine properly, as the converter will be holding it away. Severe damage to the pump, converter or transmission casting can occur if the transmission-to-engine bolts are tightened to force the transmission to mate to the engine.

Proper installation of the converter requires full engagement of the converter hub in the pump gear. To accomplish this, the converter must be pushed and at the same time rotated through what feels like 2 notches or bumps. When fully installed, rotation of the converter will usually result in a clicking noise heard, caused by the converter surface touching the housing to case bolts.

For reference, a properly installed converter will have a distance from the converter pilot nose from face-to-converter housing outer face of ¹³⁄₃₂ – ⁹⁄₁₆ in. (10.5–14.5mm).
Rotate the converter so that the drive studs are in alignment with the holes in the flywheel.
Move the converter and transmission assembly forward into position, being careful not to damage the flywheel and converter pilot. The converter housing is piloted into position by the dowels in the rear of the engine block.
NOTE: During this move, to avoid damage, do not allow the transmission to get into a nose down position as this will cause the converter to move forward and disengage from the pump gear.
Install or connect the following:
- Converter housing to engine. Torque the bolts to 30–41 ft. lbs. (40–55 Nm). The 2 longer bolts are located at the dowel holes.
- Upper fluid filler tube and bracket. Torque the bolt to 41 ft. lbs. (55 Nm).
- Transfer case, 4WD vehicles
- Exhaust bracket. Torque the bolts to 64 ft. lbs. (87 Nm).
- Crossmember. Torque the bolts to 87 ft. lbs. (118 Nm).
- Transmission mount. Torque the bolts to 81 ft. lbs. (110 Nm).
- Transmission cooler lines. Torque the bolts to 23 ft. lbs. (31 Nm).
- Starter. Torque the bolts to 30 ft. lbs. (40 Nm).
- Transmission wire harness
- HO2S sensor
- Transmission connector
- TR sensor connector
- Shift cable and bracket
- Driveshaft. Torque the bolts to 95 ft. lbs. (129 Nm).
- Shroud. Torque the bolts to 71 inch lbs. (8 Nm).
- Fluid level indicator
- Negative battery cable
Fill the transmission to the proper level.
Start the vehicle and check for leaks, repair if necessary.