Chapter
7 Part A Manual transmission
7A-3
DUST
'B
OOT
COVER
.
UPPER
BUSHING
WASHER
AX
415 and BA 1015 shift lever installation details
4 transmission mount
- check and replacement
Refer to illustration
4.2
1
Insert a large screwdriver or
into the space between the
transmission extension housing and the crossmember
models)
or the transfer case and the crossmember
models). Try to pry
the transmission or transfer case up slightly.
2
The transmission should not move away from the insulator much
at all (see illustration).
3
To replace the mount, remove the nuts attaching the insulator to
the crossmember and the bolts attaching the insulator to the trans-
mission.
4
Raise the transmission or transfer case slightly with a jack and
remove the insulator, noting which holes are used in the crossmember
for proper alignment during installation.
5
Installation is the reverse of the removal procedure. Be sure to
tighten the
securely.
4.2 Pry on the transmission mount with a
or large
screwdriver to check for excessive looseness
5 Manual transmission
removal and installation
Note: On 4
WD
models, the transmission and transfer case are removed
as a unit.
Removal
1
Disconnect the negative cable from the battery.
2
Working inside the vehicle, remove the shift lever (see Section 3). On
4WD models, disconnect the transfer case shift linkage.
3
Raise the vehicle and support it securely on jackstands.
4
Disconnect the speedometer cable and wire harness connectors
from thetransmissionandtransfercase. Unbolttheclutch releasecvlinder
from theclutch housing (external cylinder) or disconnectthe
line
at the transmission (see Chapter 8).
5
Remove the
(see Chapter 8). Use a plastic bag to cover
the end of the transmission to prevent fluid loss and contamination.
6
Removethe exhaust system components as necessary for clearance
(see Chapter 4).
7
Support the engine. This can be done from above with an engine
hoist, or by placing a jack (with a block of wood as an insulator) under the
engine oil pan. The engine should remain supported at all times while the
transmission is out of the vehicle.
8
Supportthe transmission with ajack-preferably a special jack made
for this purpose. Safety chains will help steady the transmission on the
jack. Warning: On 4WD models, do not attempt to remove the
case assembly without a transmission jack and safety
chains. The assembly is very heavy and awkward to remove.
9
Remove the rear transmission (or transfer case)
member nuts and bolts.
10 Remove the nuts from the crossmember bolts. Raise the transmis-
sion slightly and remove the crossmember.
11 Remove the bolts securing the clutch housing to the engine.
12 Make a final check that all wires and hoses have been disconnected
from thetransmission
movethetransmission and jacktoward the
rear of the vehicle until the transmission input shaft is clear of the clutch
housing. On 2WD models, keep the transmission level as this is done. On
models, the
assembly is too long to
be removed with the engine level. You may need to lower the rear of the
engine to provide sufficient clearance for removal. The fan could contact
the shroud during this operation, so it is a good idea to place a block of
wood between the rear of the cylinder
and the
to limit the
distance the rear of the engine drops.
13 Once the input shaft is clear, lower the transmission and remove it
from
vehicle. Caution:
depress the clutchpedal while the
transmission is out of the vehicle.
14 The clutch components can be inspected by removing the clutch
housing from the engine (see Chapter 8). In most cases, new clutch com-
ponents should be routinely installed if the transmission is removed.
15 If removed, install the clutch components (see Chapter 8).
16 With the transmission secured to the jack as on removal, raise the
transmission into position behind the engine and then carefully slide it for-
ward, engaging the input shaft with theclutch plate hub. Do not use exces-
sive force to install the transmission
- if the input shaft does not slide into
place, readjust the angle of the transmission so it is level
turn the
input shaft so the splines engage properly with the clutch.
17
housing-to-engine bolts. Tighten the bolts to the spe-
cified torque.
18 Install the crossmember and transmission support. Tighten all nuts
and bolts securely.
19 Remove the jacks supporting the transmission and the engine.
20 Install the various items removed previously, referring to Chapter 8
installation of the driveshaft and
information regarding
the exhaust system components. If the hydraulic line was disconnected,
bleed the clutch hydraulic system (see Chapter 8).
21 Make a final check that all wires, hoses and the speedometer cable
have been connected and that the transmission has been filled with lubri-
cant to the proper level (see Chapter 1). Lower the vehicle.
22 Working inside the vehicle, install the shift lever (see Section
4WD models, connect the transfer case shift linkage.
23 Connect the negative battery cable. Road test the vehicle for
operation and check for leakage.
The Motor Manual Guy
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