Page 2593 of 5267
4. Remove fill plug (1) from side of transmission (2).
5. Fill transmission even with the bottom of the fill
hole.
6. Install fill plug and tighten to 50 Nꞏm (37 ft. lbs.).
REMOVAL
1. With vehicle in neutral, position vehicle on hoist.
2. Disconnect battery negative cable.
3. Remove shift boot bezel screws and slide boot
upward on shift lever extension.
4. Remove shift lever extension from the shift tower
and lever assembly.
5. Remove 4WD shift boot if equipped and remove
floor console.
6. Remove skid plate, if equipped.
7. Remove drain plug (1) from rear housing (2) and
drain fluid.
8. Mark propeller shaft/shafts and companion flange
yoke/yokes for installation reference and remove
propeller shaft/shafts.
9. Disconnect harness from clips on transmission
housing.
10. Remove transfer case linkage if equipped.
11. Remove transfer case mounting nuts and remove
transfer case if equipped.
12. Remove slave cylinder (2) mounting nut (1) and
remove cylinder.
Page 2594 of 5267
13. Remove starter motor (2), structural dust cover (3)
bolts to clutch housing, dust shield (1) bolt and
suspension crossmember (4).
CAUTION: Do not remove structural dust cover
from engine block. If cover is removed clutch
housing and cover must be aligned with the
engine.
14. Remove exhaust pipe from the exhaust manifolds.
15. Support engine with adjustable jack stand and
wood block.
16. Support and secure transmission (1) to a trans-
mission jack (2) with safety chains.
17. Remove bolts from the rear transmission mount.
18. Remove the rear crossmember (2) and transmis-
sion mount (1).
19. Remove bolts attaching transmission to the
engine.
20. Move transmission rearward until input shaft is
clear of clutch disc and pressure plate. Then
lower jack and remove transmission from under
vehicle.
Page 2595 of 5267
DISASSEMBLY
1. Remove shifter socket (1) from main shift rail.
2. Remove back up lamp switch (1) bolt (2) and
remove switch.
Page 2596 of 5267
3. Remove large detent plug, next to back up lamp
switch opening with Puller 9583 (1) and Slide Ham-
mer C-3752 (2).
4. Remove two small detent plugs on top of rear
housing with Puller 8870 (2) and Slide Hammer
C-3752 (1).
5. Install Wrench 9586 (1) on input shaft (2).
Page 2597 of 5267
6. Remove output flange (1) nut (2) on 4x2 transmis-
sion.
7. Remove output flange (1) on 4x2 transmission with
Puller 8992 (2) and Button 9618-2.
8. Remove output shaft nut with Socket 9584 (1) on
4x4 transmission (2).
9. Remove Wrench 9586 from input shaft.
Page 2598 of 5267
10. Place transmission on front housing and remove
rear housing (2) bolts (1). If necessary, remove
the cover plate to access the one rear housing (2)
bolt (1) located in the opening.
11. Install Button 9618-2 (1) into output shaft (2).
12. Separate rear housing (1) from mainshaft with
Puller 9621(2). Bolt puller to the bottom of the
rear housing, then turn puller bolt to push main-
shaft out of the housing.
Page 2599 of 5267
13. Remove reverse shift fork roll pin (1) from reverse
shift rail (2).
14. Slide reverse shift rail (1) down out of the shift
fork (2) and remove reverse shift fork. Then slide
shift rail up and out of the front housing.
15. Remove 1-2 shift fork roll pin (1) from shift rail (2).
Slide shift rail up out of shift fork and rear hous-
ing. Remove 1-2 shift fork.
Page 2600 of 5267
16. Rotate main shift rail (1) clockwise and pull up
and out of the front housing.
17. Remove first gear, reverse gear, reverse bearing,
reverse gear bearing race and reverse synchro-
nizer with Bridge 938 (1), Button 9618-2 (2) and
puller Adapters 9628 (3). Position puller Adapters
9628 (3) under first gear.