Removal and Installation

REMOVAL AND INSTALLATION

ZF S6-40 6-Speed Manual Transmission:

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Console trim plate. .
3. Complete exhaust system.
4. Bolts retaining driveline torque beam. Slide beam outboard to gain access to driveshaft.
5. Parking brake cable clip.
6. Bolts retaining support bracket.
7. Bolts retaining propeller shaft to yoke at differential carrier and propeller shaft.

IMPORTANT
^ To maintain proper drivetrain balance, mark the position of the U-joint in relationship to the differential carrier yoke before removal.

8. Slide driveline torque beam rearward until it makes contact with the rear exhaust hanger.
9. Support transmission with suitable jack.
10. Connectors at Vehicle Speed Sensor (VSS), backup lamp switch and computer aided gear select solenoid.
11. Transmission to clutch housing retaining bolts and remove transmission.

INSTALL OR CONNECT
1. Bolts retaining transmission to clutch housing and support with suitable jack.

TIGHTEN
^ Bolts retaining transmission to clutch housing 50 Nm (37 lb. ft.). (Refer to image for torque sequence.)

2. Connectors at VSS, backup lamp switch and computer aided gear select solenoid.
3. Slide driveline torque beam forward onto transmission extension housing.
4. Propeller shaft and retaining bolts. Install driveshaft onto yoke in same position as removed noting marked areas.

TIGHTEN
^ Propeller shaft to yoke retaining bolts to 24 Nm (18 lb. ft.).

5. Bolts retaining support bracket.

TIGHTEN
^ Bolt to support bracket to 25 Nm (18 lb. ft.).

6. Check transmission oil level and fill if necessary.
7. Parking brake cable clip.
8. Align driveline torque beam and install retaining bolts.

TIGHTEN
^ Driveline torque beam to differential carrier retaining bolt 80 Nm (60 lb. ft.).
^ Driveline torque beam to transmission retaining bolt 50 Nm (37 lb. ft.).

9. Complete exhaust system.
10. Console trim plate.
11. Negative battery cable.