Manual Transmission Assembly

Removal & Installation

To Remove:

4x2 Vehicles

1. As an assembly, remove the upper gearshift lever, the outer gearshift lever boot, and the console.
2. Put the vehicle in NEUTRAL then raise and safely support the vehicle.
3. If it is necessary to disassemble the transmission, remove the drain plug and drain the transmission fluid. Once finished, install the drain plug and torque to 36 ft-lb (48 Nm).

   NOTE: Mark the driveshaft yoke and axle flange before removal to ensure alignment to their original positions and maintenance of the initial driveshaft balance at installation.

4. Remove the transfer case.
5. Disconnect the wire harness from the crossmember.

   CAUTION
   Do not let the transmission hang freely.

6. Place an appropriate jack under the transmission and secure the transmission to the jack with a safety strap.
7. Remove the 6 crossmember bolts.
8. Remove the transmission mount nuts and the crossmember.
9. Remove the heated oxygen sensor (HO2S) bracket nut and bracket from the extension housing.
10. Remove the transmission mount by first removing the bolts on it.
11. Remove the catalytic converter Y-pipe.
12. Disconnect the electrical connectors for the vehicle speed sensor (VSS) and the reverse lamp switch. Next, unclip the wiring harness from the transmission.

    CAUTION
    Do not let the starter hang freely.

13. Remove the starter motor. Move the starter to the side by using mechanics’ wire.
14. Use the hydraulic line disconnect tool (308-182) to disconnect the clutch hydraulic line.
15. Support the engine using an appropriate jack.

    NOTE: To get access to the upper transmission-to-engine bolts, lower the transmission as much as needed for access.

16. Remove the 9 transmission-to-engine bolts.
17. Pull the transmission toward the rear until the input shaft is clear of the pressure plate, then lower the transmission from the vehicle.

To Install:

NOTE: Connect the hydraulic line to the clutch slave cylinder before you secure the engine to the transmission.

NOTE: Make sure to install the transfer case with a new gasket. Torque the bolts that fasten the transfer case to the extension housing in a clockwise direction starting with the upper left-hand bolt.

1. Raise the transmission into the vehicle.
2. Install the 9 transmission-to-engine bolts.
   • Torque to 41 ft-lb (55 Nm).
3. Remove the jack.
4. Connect the clutch hydraulic line.
5. Install the starter motor.
   • Torque to 18 ft-lb (25 Nm).
6. Clip the wiring harness to the transmission.
7. Connect the electrical connectors for the VSS and the reverse lamp switch.
8. Install the catalytic converter Y-pipe.
9. Install the transmission mount.
   • Torque the bolts to 73 ft-lb (99 Nm).
10. Install the HO₂S bracket to the extension housing.
    • Torque to 29 ft-lb (39 Nm).
11. Install the crossmember and transmission mount nuts.
    • Torque to 72 ft-lb (98 Nm).
12. Install the 6 crossmember bolts.
    • Torque to 74 ft-lb (101 Nm).
13. Remove the jack from under the transmission.
14. Connect the wire harness to the crossmember.
15. Install the transfer case.
16. Fill with the correct type and amount of fluid, if necessary.
17. Safely lower the vehicle.
18. As an assembly, install the upper gearshift lever, the outer gearshift lever boot, and the console.

To Remove:

4x4 Vehicles

1. As an assembly, remove the upper gearshift lever, the outer gearshift lever boot, and the console.
2. Put the vehicle in NEUTRAL then raise and safely support the vehicle.
3. If present, remove the skid plate.
4. If it is necessary to disassemble the transmission, remove the drain plug and drain the transmission fluid. Once finished draining the fluid, install the drain plug and torque to 36 ft-lb (48 Nm).

   NOTE: Mark the rear driveshaft yokes before removal to ensure alignment to their original positions and maintenance of the initial driveshaft balance at installation.

5. Remove the driveshaft.
6. Disconnect the wire harness from the crossmember.

   CAUTION
   Do not let the transmission hang freely.

7. Place an appropriate jack under the transmission and secure the transmission to the jack with a safety strap.
8. Remove the crossmember bolts.
9. Remove the transmission mount nuts and crossmember.
10. Remove the heated oxygen sensor (HO2S) bracket nut and bracket from the extension housing.
11. Remove the catalytic converter Y-pipe.
12. Disconnect the electrical connectors for vehicle speed sensor (VSS) and the reverse lamp switch. Next, unclip the wiring harness from the transmission.

    CAUTION
    Do not let the starter hang freely.

13. Remove the starter motor. Move it to the side using mechanics’ wire.
14. Using the hydraulic line disconnect tool (308-182), disconnect the clutch hydraulic line.
15. Support the engine with an appropriate jack.

    NOTE: To get access to the upper transmission-to-engine bolts, lower the transmission as much as needed for access.

16. Remove the 9 transmission-to-engine bolts.
17. Pull the transmission toward the rear until the input shaft is clear of the pressure plate, then lower the transmission from the vehicle.

To Install:

NOTE: Connect the hydraulic line to the clutch slave cylinder before you secure the engine to the transmission.

NOTE: Make sure to install the transfer case with a new gasket. Torque the bolts that fasten the transfer case to the extension housing in a clockwise direction starting with the upper left-hand bolt.

1. Raise the transmission into the vehicle.
2. Install the 9 transmission-to-engine bolts.
   • Torque to 41 ft-lb (55 Nm).
3. Remove the jack from under the engine.
4. Connect the clutch hydraulic line.
5. Install the starter motor.
   • Torque to 18 ft-lb (25 Nm).
6. Clip the wiring harness to the transmission.
7. Connect the electrical connectors for the VSS and the reverse lamp switch.
8. Install the catalytic converter Y-pipe.
9. Install the HO₂S bracket to the extension housing.
   • Torque to 29 ft-lb (39 Nm).
10. Install the transmission mount nuts and crossmember.
    • Torque to 72 ft-lb (98 Nm).
11. Install the crossmember bolts.
    • Torque to 46 ft-lb (63 Nm).
12. Remove the jack from under the transmission.
13. Connect the wire harness to the crossmember.
14. Install the driveshaft.
15. Fill with the correct type and amount of fluid, if necessary.
16. If equipped, install the skid plate.
    • Torque to 18 ft-lb (24 Nm).
17. Safely lower the vehicle.
18. As an assembly, install the upper gearshift lever, the outer gearshift lever boot, and the console.