Service Procedure

SERVICE PROCEDURE - Note: 1991 R/V Model Service Manuals should begin arriving in dealerships around September 14.

Tool Required: J-21366 Converter Holding Strap

1. Remove negative battery cable.

2. Raise vehicle.

3. Drain transmission fluid (transmission pan seal is reusable).

4. Remove shift linkage.

5. Remove Propeller Shaft(s). Refer to "Propeller Shaft", Section 4A, 1991 R/V Model Service Manual.

6. Remove support bracket at catalytic converter and any other components as needed for clearance. Support transmission, and transfer case if equipped, with a transmission jack.

7. Remove transmission crossmember.

8. Lower transmission far enough for clearance to reach other components.

NOTICE: Do not stretch or damage any wires or other components when lowering transmission.

9. Remove transmission dipstick tube and seal. Cover opening in transmission.

10. Disconnect electrical connectors from the transmission.

NOTICE: Do not bend or damage connector pins.

11. Remove cooler lines. Cap openings in transmission and lines.

12. Disconnect transfer case shifter (if equipped) and move aside. Refer to "Transfer Case", Section 7D, 1991 R/V Model Service Manual.

13. Remove Transmission support brace. Be sure to note location of braces as they must be reinstalled in same positions.

14. Remove converter housing cover.

15. Remove torque converter to flexplate bolts.

NOTICE: Support engine with jack or hoist before disconnecting transmission.

16. Remove transmission to engine bolts. Note location of any brackets or braces and move aside. Slide transmission straight back off locating pins and install J-21366 Converter Holding Strap.

17. Remove Transmission from vehicle.
18. Remove holding strap and converter.

NOTICE: Converter is extremely heavy (65 lbs.) when full of fluid. Make sure you have a good, clean grip to help prevent personal injury.

19. Remove turbine shaft O-ring seal.

20. Install new turbine shaft O-ring seal.

21. Install new converter assembly as follows:

a. With transmission in horizontal position, push new converter in until the hub is into converter seal.

NOTICE: Take care not to cut seal when installing converter.

b. Rotate transmission to a vertical position (Bell housing facing up).

c. Rotate converter until it drops into position.

22. Install transmission assembly as follows:

a. Attach J-21366 converter holding strap to converter assembly.

b. Raise transmission into place and remove J-21366.

NOTICE: Do not pinch or damage any wires or other components when raising transmission.

c. Slide transmission straight onto locating pins while lining up torque converter and flexplate.

NOTICE: Torque converter must be flush onto flywheel and rotate freely by hand.

23. Install Transmission to engine bolts. Torque to 44 N-m. (33 lbs. ft.).

24. Position all brackets, clips and harnesses as when removed. Do not reinstall transmission dipstick tube or transmission support brace bolts.

25. Install torque converter to flexplate bolts. Torque to 44 N-m (33 lbs.ft.).

26. Remove engine support.

27. Install converter housing cover. Hook pan under lip of engine oil pan. Torque bolts to 7 N-m. (60 lbs.in.).

28. Install transmission support braces. Braces must be installed in same positions as when removed. Torque bolts to 90 N-m. (66 lbs.ft.).
29. Install transfer case shifter (if equipped). Refer to "Transfer case", Section 7D, 1991 R/V Model Service Manual.

30. Uncover transmission and cooler line openings, and install cooler lines. Do not bend or twist lines. Torque fittings to 38 N-m. (28 lbs. ft.).

31. Reconnect electrical connectors to transmission.

NOTICE: Do not bend or damage connector pins.

32. Uncover dipstick tube opening and install new seal.

33. Install dipstick tube with retainer bolt. Torque bolt to 44 N-m. (33 lbs. ft.).

34. Install transmission crossmember, transmission mount, and any other components which were removed for clearance. Torque crossmember and transmission mount bolts to 44 N-m. (33 lbs. ft.). Remove transmission jack.

35. Install support bracket at catalytic converter.

36. Install propeller shaft(s). Refer to "Propeller Shaft", Section 4A, 1991 R/V Model Service Manual.

37. Reinstall shift linkage.

38. Add new transmission fluid.

39. Install negative battery cable.

40. Install Campaign Identification Label.