•
• release fork ball stud
• propeller shaft slip yoke
APPLY
LIGHT
COAT
OF
HI-TEMP
GREASE
TO
THESE
SURFACES
BEFORE
INSTALLATION
J9106-15
Fig.
18 input Shaft Lubrication
Points
(Typical)
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re lease bearing and clutch disc hub. Rotate output
shaft with socket or yoke to align input shaft and
clutch disc splines if necessary.
(4) Move transmission forward and seat transmis
sion against housing. (5) Install and tighten transmission mounting
bolts to 68 N-m (50 ft-lbs). (6) Install rear crossmember and crossmember
brackets. Start all crossmember bolts/nuts before
tightening to final torque of 68 N»m (50 ft-lbs). (7) Remove transmission jack.
(8) Install screws that attach fuel line clamps to
driver side frame rail. (9) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (10) Install clutch slave cylinder shield.
(11) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(12) Align and install propeller shaft. Support
shaft on box or stand. Install shaft front U-joint first.
Next, secure center bearing bracket to frame bracket.
Then install shaft rear U-joint in axle yoke. Final- tighten U-joint clamp bolts to 19 N@m (14 ft-lbs) and center bearing bracket bolts to 68 N»m (50 ft-lbs). (13) Lower vehicle.
(14) Lubricate shift lever ball and collar with Mo
par all purpose grease. (15) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (16) Press shift lever and collar downward and in
stall shift lever snap ring. (17) Tighten shift lever alignment bolts com
pletely. (18) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (19) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large G360
MANUAL TRANSMISSION
21 - 51
SKID
PLATE
J9121-525
Fig.
19 Transfer
Case
Skid
Plate
Mounting
notch is forward then install lower boot attaching
screws. (20) Thread or bolt shift lever extension to shift le
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws.
(21) Install shift knob on extension (if removed). (22) Connect battery negative cable.
TRANSMISSION REMOVAL—4-WHEEL DRIVE
(1) Disconnect battery negative cable.
(2) Remove screws attaching shift lever upper boot
to metal plate on lower boot. Then slide boot upward on lever (Fig. 3).
(3) Remove screws attaching lower boot and plate
assembly to floor pan (Fig. 4). (4) Remove shift lever extension by unthreading it
from shift lever (Fig. 5). (5) Slide lower boot and plate upward and off shift
lever (Fig. 6). (6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).
(7)
Remove snap ring securing shift lever in shift
tower (Fig. 8). (8) Remove shift lever (Fig. 9). If lever does not
come out readily, press lever downward and quickly
release it two or three times. Pressure from spring under lever should push it out of housing. Note alignment slots in lever cover and pivot ball
(Fig. 9). These slots align with shoulder bolts in
shift tower.
(9) Raise and support vehicle.
(10) Mark front and rear propeller shafts for in
stallation reference (Fig. 10). Then disconnect and re
move both shafts. (11) Remove transfer case skid plate and cross-
member (Fig. 19).
