Manual Transmission/Transaxle: Service and Repair
Transmission Replacement
Removal Procedure
Important:
* Remove components in order to provide clearance for transmission removal, if necessary.
* The vehicles have either an apron clutch housing (2) or an SAE number 2 (6) type flywheel housing.
* The apron-type clutch has a sheet metal pan which covers the entire lower portion of the clutch and flywheel. The clutch housing is not separate.
* The SAE number 2 type flywheel housing also surrounds the flywheel. The SAE number 2 type flywheel housing uses a separate clutch housing. Transmission replacement procedures are different for each type of flywheel housing.
1. Block the wheels of the vehicle.
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
2. Disconnect the negative battery cable.
Important: Before you disconnect any air operated components or air lines, bleed all air pressure from the system.
Check what type of front engine mount is used. If a single cushion center mount is used, support the engine with an overhead hoist during transmission or clutch replacement.
Important: When removing or installing the transmission, use a transmission dolly jack in order to support the weight of the transmission. Fasten a safety chain over the top of the transmission and to both sides of the dolly.
3. Shift the transmission into neutral.
4. Remove the air shift controls from the shift lever. Refer to Air Shift Control Valve Replacement Air Shift Control Valve Replacement.
5. Remove the screws from the shift lever boot retainer.
6. Remove the retainer from the shift boot.
7. Remove the shift boot.
8. For the 7.4 L engines, remove the shift lever.
9. Remove the clutch cable from the transmission. Refer to Clutch Assembly Adjustment (14 Inch Valeo Internal) Clutch Assembly Adjustment (14 Inch Valeo Internal)Clutch Assembly Adjustment (Dana/Spicer Internal) Clutch Assembly Adjustment (Dana/Spicer Internal)Clutch Assembly Adjustment (13 Inch Valeo Cable) Clutch Assembly Adjustment (13 Inch Valeo Cable)Clutch Assembly Adjustment (14 Inch Valeo Cable) Clutch Assembly Adjustment (14 Inch Valeo Cable).
10. Remove the following components from the shift control lever:
* The retainers
* The bushings
* The pin
11. Remove the electric connectors, as necessary.
12. Remove the air lines from the air shift control valve.
13. Remove the oil from the transmission. Refer to Transmission Oil Changing Service and Repair.
14. Remove the muffler, if required. Refer to Exhaust System Replacement Service and Repair.
15. Remove the parking brake lever and controls, if used. Refer to Park Brake Cable Replacement in Park Brake.
16. Remove the propeller shaft. Refer to the proper procedure:
* The one piece propeller shaft:
- Propeller Shaft Replacement - One Piece - Flange Type Propeller Shaft Replacement - One Piece - Flange Type
- Propeller Shaft Replacement - One-Piece - Yoke Type Propeller Shaft Replacement - One-Piece - Yoke Type
* The two piece propeller shaft:
- Propeller Shaft Replacement - Two Piece - Flange Type Propeller Shaft Replacement - Two Piece - Flange Type
- Propeller Shaft Replacement - Two Piece - Yoke Type Propeller Shaft Replacement - Two Piece - Yoke Type
* The three piece propeller shaft:
- Propeller Shaft Replacement - Three Piece - Flange Type Propeller Shaft Replacement - Three Piece - Flange Type
- Propeller Shaft Replacement - Three Piece - Yoke Type Propeller Shaft Replacement - Three Piece - Yoke Type
17. Remove the power take-off and controls, if used.
* Place a protective cover over the opening.
* Position a transmission dolly jack under the vehicle. Adjust the dolly jack in order to carry the weight of the transmission.
18. Remove the rear support beam, if used.
Notice: When removing the transmission, do not allow the weight of the transmission to hang on the clutch disc hub. The clutch disc will become distorted and seriously affect the operation of the clutch.
19. In order to remove the transmission from the engine (SAE number 2 flywheel housing), perform the following procedure :
1. If the engine rear mounting is attached to the transmission, support the engine weight with a hoist or jack.
2. Remove the engine rear mount bolts. Refer to Engine Mount Replacement Service and Repair in Engine Mechanical.
3. Adjust the transmission dolly in order to support the transmission's weight.
4. Remove all bolts attaching the clutch housing to the engine.
5. Move the transmission straight back from the engine. Keep the mainshaft in alignment with the clutch disc hub.
6. When the transmission is free from the engine, lower and remove the transmission from beneath the vehicle.
20. In order to remove the transmission from the engine (Apron-type flywheel housing), perform the following procedure:
1. Remove the cover from the bottom of the clutch housing (optional).
2. Remove the lower transmission to flywheel housing bolts from the clutch housing.
3. Remove the remaining upper attaching bolts.
4. Move the transmission straight back from the engine. Keep the transmission mainshaft in alignment with the clutch disc hub.
5. When the transmission is free from the engine, lower and remove the transmission from the vehicle.
Installation Procedure
1. Shift the transmission into high gear.
2. Mount the transmission on a suitable dolly and move the transmission into position under the vehicle.
3. Rotate the output flange or yoke to align the main drive gear shaft with the clutch disc hub.
Notice: When removing the transmission, do not allow the weight of the transmission to hang on the clutch disc hub. The clutch disc will become distorted and seriously affect the operation of the clutch.
4. Move the transmission forward, guiding the main drive gear shaft into the clutch disc splines.
Install the transmission into the vehicle.
* Avoid springing the clutch when you install the transmission.
* Do not let the transmission drop or hang unsupported in the splined hub of the clutch disc.
Notice: Refer to Fastener Notice in Cautions and Notices.
5. In order to install 2 type flywheel housing, install the bolts and washers that attach the transmission clutch housing to the transmission flywheel housing.
Tighten all the attaching bolts to 44 Nm (32 lb ft).
6. In order to install apron type flywheel housing, perform the following steps:
1. Install the upper bolts and washers that attach the transmission to the flywheel housing.
2. Install the lower bolts and washers that attach the transmission to the flywheel housing.
Tighten all the attaching bolts to 142 Nm (105 lb ft).
3. Install the rear support beam, if used.
4. Measure the space between the outer ends of the support beam and cushion assembly.
5. Select spacers equal to this gap.
6. If there is a difference in the gap between the left and right sides of the rear mounting, measure the total gap between the left and the right sides and divide by two.
7. Remove the dolly.
7. Install the power take-off and the controls, if used.
8. Install the propeller shaft. Refer to the proper procedure:
* The one piece propeller shaft:
- Propeller Shaft Replacement - One Piece - Flange Type Propeller Shaft Replacement - One Piece - Flange Type
- Propeller Shaft Replacement - One-Piece - Yoke Type Propeller Shaft Replacement - One-Piece - Yoke Type
* The two piece propeller shaft:
- Propeller Shaft Replacement - Two Piece - Flange Type Propeller Shaft Replacement - Two Piece - Flange Type
- Propeller Shaft Replacement - Two Piece - Yoke Type Propeller Shaft Replacement - Two Piece - Yoke Type
* The three piece propeller shaft:
- Propeller Shaft Replacement - Three Piece - Flange Type Propeller Shaft Replacement - Three Piece - Flange Type
- Propeller Shaft Replacement - Three Piece - Yoke Type Propeller Shaft Replacement - Three Piece - Yoke Type
9. Install the parking brake lever and the controls, if used. Refer to Park Brake Lever Assembly Replacement in Brakes.
10. Install the clutch cable. Refer to Clutch Assembly Adjustment (14 Inch Valeo Internal) Clutch Assembly Adjustment (14 Inch Valeo Internal)Clutch Assembly Adjustment (Dana/Spicer Internal) Clutch Assembly Adjustment (Dana/Spicer Internal)Clutch Assembly Adjustment (13 Inch Valeo Cable) Clutch Assembly Adjustment (13 Inch Valeo Cable)Clutch Assembly Adjustment (14 Inch Valeo Cable) Clutch Assembly Adjustment (14 Inch Valeo Cable).
11. Install the muffler, as necessary. Refer to Exhaust System Replacement Service and Repair
12. Install the electrical connectors, as necessary.
13. Install the air lines to the transmission, as used.
14. For the 7.4 L engines, install the shift lever.
15. Install the following components to the control lever:
* The pin
* The bushings
* The retainers
Apply a small amount of grease around the pin prior to installation.
16. Install the retainer to the shift boot with screws.
17. Install the air shift controls to the shift lever. Refer to Air Shift Control Valve Replacement Air Shift Control Valve Replacement.
18. Fill the transmission with transmission oil. Refer to Transmission Oil Changing Service and Repair.
19. Install the parking brake, if used. Refer to Park Brake Cable Replacement in Park Brake.
20. Install the clutch cable. Refer to Clutch Assembly Adjustment (14 Inch Valeo Internal) Clutch Assembly Adjustment (14 Inch Valeo Internal)Clutch Assembly Adjustment (Dana/Spicer Internal) Clutch Assembly Adjustment (Dana/Spicer Internal)Clutch Assembly Adjustment (13 Inch Valeo Cable) Clutch Assembly Adjustment (13 Inch Valeo Cable)Clutch Assembly Adjustment (14 Inch Valeo Cable) Clutch Assembly Adjustment (14 Inch Valeo Cable).