Transmission Replacement

Transmission Replacement

Removal Procedure




1. Remove vehicle components only if necessary, in order to provide adequate clearance for transmission removal.
2. The vehicle will be equipped with one of the following:

* Apron-type flywheel housing (2)
* SAE number 2 type flywheel housing (6)

- The apron-type flywheel housing (2) has a sheet metal pan which covers the lower portion of the clutch and flywheel. The flywheel housing is attached separately from the transmission body.
- The SAE number 2 type flywheel housing (6) surrounds the entire clutch flywheel. The flywheel housing is not separate from the transmission body.

3. Transmission replacement procedures differ slightly between the two types of housings.




4. Block the front and rear wheels.
5. Ensure that the transmission is in neutral.
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

6. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
7. Drain the transmission fluid. Refer to Transmission Oil Change Procedure Transmission Oil Change Procedure.
8. Remove the control lever and/or boot. Refer to Control Lever and/or Boot Replacement Control Lever and/or Boot Replacement.
9. Remove the transmission air shift harness. Refer to Transmission Air Shift Harness Replacement Transmission Air Shift Harness Replacement.




10. If equipped with regular production options (RPOs) MWW/MWX, remove the clutch return spring from the bracket and fork.




11. If equipped with the 6.6L or 7.2L engine, and RPOs MUT/MS9/MT3/MK0/ML0, remove the clutch return spring from the bracket and lever.




12. If equipped with the 6.6L or 7.2L engine, and RPOs M69/MK8/MK9 and MWW, remove the clutch return spring from the bracket and cable swivel.




13. If equipped with the 7.2L engine and RPOs MS9/MT3, remove the clutch cable retainer (1).
14. Remove the adjustment rod swivel (5) from the lever.




15. Remove the clutch cable bracket nuts and washers.
16. Remove and reposition the clutch cable bracket and cable.




17. If equipped with the 6.6L or 7.2L engines and RPOs MUT/MS9/MT3, remove the clutch cable retainer (1).
18. Remove the adjustment rod swivel (5) from the lever.
19. Remove the clutch cable bracket nuts and washers.
20. Remove and reposition the clutch cable bracket and cable.




21. If equipped with the 6.6L engine and RPOs MTD/MK8/MK9 and MWW, remove the clutch cable retainer (1).
22. Remove the adjustment rod swivel (5) from the lever.




23. Remove the clutch cable bracket bolts.
24. Remove and reposition the clutch cable bracket and cable.




25. If equipped with the 6.6L or 7.2L engines and RPOs MK0/ML0/MM7/MNC and MPU, remove the clutch cable retainer (3).
26. Remove the adjustment rod swivel (1) from the lever.




27. Remove the clutch cable bracket bolts and washers.
28. Remove and reposition the clutch cable bracket and cable.




29. If equipped with the 8.1L engine and RPOs MM7/MNC/MPU/MSC/MSG and MPJ, remove the cable nuts (2) and retainer (1).




30. Remove the clutch cable bracket bolts and washers.
31. Remove and reposition the clutch cable bracket and cable.




32. Disconnect the engine harness electrical connector from the transmission connector (1) (typical).
33. If equipped with the 8.1L engine, remove the muffler. Refer to Muffler Replacement Service and Repair in Engine Exhaust.




34. If equipped with the 6.6L or 7.2L engine, loosen the band clamp (2) joining the exhaust manifold front (3), and rear (1) pipes.




35. If equipped with the 6.6L or 7.2L engine without PRO K40, perform the following:

* Loosen the exhaust manifold front pipe clamp nut.
* Remove the U-bolt nuts and U-bolt.
* Remove the exhaust manifold front pipe.




36. If equipped with the 6.6L or 7.2L engine with RPO K40, perform the following:

* Loosen the exhaust manifold front pipe clamp nut.
* Remove the U-bolt nuts and U-bolt.
* Remove the exhaust manifold front pipe.

37. Remove the propeller shaft. Refer to Propeller Shaft Replacement - One Piece Propeller Shaft Replacement - One Piece , Propeller Shaft Replacement - Two Piece Propeller Shaft Replacement - Two Piece , or Propeller Shaft Replacement - Three Piece Propeller Shaft Replacement - Three Piece in Propeller Shaft.
38. If equipped, remove the power take-off (PTO) and controls. Install a protective cover over the PTO opening.





Important: When removing or installing the transmission, use a transmission dolly jack in order to support the weight of the transmission. Fasten safety chains over the top and to both sides of the dolly.


39. Position the dolly jack under the transmission. Adjust the dolly jack in order to support the weight of the transmission.




40. If equipped with the apron-type flywheel housing, remove the flywheel housing cover bolts and cover.




41. If equipped with a apron-type flywheel housing, remove the clutch fork return spring bracket, caution tag, and housing cover extension bolts.




42. If equipped with the apron-type flywheel housing, remove the flywheel housing bolts.




43. If equipped with the 6.6L or 7.2L engine with RPOs, MK8/MK9, remove the transmission support bolts and washers.




44. If equipped with RPOs, MS9/MT3, remove the transmission support nuts, washers, and spacers.




45. If equipped with the SAE number 2 flywheel housing, remove the transmission bolts and exhaust manifold front pipe bracket.




46. If equipped with the SAE number 2 flywheel housing, remove the transmission bolts.
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.

47. Move the transmission straight back from the engine, keep the mainshaft in alignment with the clutch disc hub.
48. When the transmission is free from the engine, lower and remove the transmission.

Installation Procedure




1. Shift the transmission into high gear.
2. With the transmission mounted to a suitable dolly, move the transmission into position under the vehicle.
3. Rotate the output shaft to align the main drive gear shaft with the clutch disc hub.
4. Move the transmission forward, guiding the main drive gear shaft into the clutch disc hub.
5. Install the transmission.

* Avoid springing the clutch when installing the transmission.
* Do not allow the transmission to drop or hang unsupported in the splined hub of the clutch disc.




6. If equipped with the SAE number 2 flywheel housing, install the transmission bolts.





Notice: Refer to Fastener Notice in Cautions and Notices.

7. If equipped with the SAE number 2 flywheel housing, install the exhaust manifold front pipe bracket and transmission bolts.

Tighten the transmission bolts to 50 Nm (37 lb ft).




8. If equipped with RPOs, MS9/MT3, install the transmission spacers, washers, and support nuts.

Tighten the nuts to 163 Nm (120 lb ft).




9. If equipped with the 6.6L or 7.2L engine with RPOs, MK8/MK9, install the transmission support bolts and washers.

Tighten the bolts to 195 Nm (144 lb ft).




10. If equipped with the apron-type flywheel housing, install the flywheel housing bolts.

Tighten the bolts to 67 Nm (49 lb ft).




11. If equipped with a apron-type flywheel housing, install the clutch fork return spring bracket, caution tag, and housing cover extension bolts.

Tighten the bolts to 43 Nm (32 lb ft).




12. If equipped with the apron-type flywheel housing, install the flywheel housing cover and bolts.

Tighten the bolts to 12 Nm (106 lb in).

13. If equipped, remove the protective cover over the PTO opening. Install the PTO and controls.
14. Install the propeller shaft. Refer to Propeller Shaft Replacement - One Piece Propeller Shaft Replacement - One Piece , Propeller Shaft Replacement - Two Piece Propeller Shaft Replacement - Two Piece , or Propeller Shaft Replacement - Three Piece Propeller Shaft Replacement - Three Piece in Propeller Shaft.




15. If equipped with the 6.6L or 7.2L engine with RPO K40, perform the following:

* Install the exhaust manifold front pipe.
* Install the U-bolt and nuts.

Tighten the nuts to 24 Nm (18 lb ft).

* Tighten the exhaust manifold front pipe clamp nut.

Tighten the nut to 10 Nm (89 lb in).




16. If equipped with the 6.6L or 7.2L engine without PRO K40, perform the following:

* Install the exhaust manifold front pipe.
* Install the U-bolt and nuts.

Tighten the nuts to 24 Nm (18 lb ft).

* Install the exhaust manifold front pipe clamp nut.

Tighten the nut to 10 Nm (89 lb in).




17. If equipped with the 6.6L or 7.2L engine, tighten the band clamp (2) joining the exhaust manifold front (3), and rear (1) pipes.
18. If equipped with the 8.1L engine, install the muffler. Refer to Muffler Replacement Service and Repair in Engine Exhaust.




19. Connect the engine harness electrical connector to the transmission connector (1) typical.




20. Install and position the clutch cable bracket and cable.
21. Install the clutch cable bracket bolts and washers.

Tighten the bolts to 93 Nm (69 lb ft).




22. If equipped with the 8.1L engine and RPOs MM7/MNC/MPU/MSC/MSG and MPJ, install the cable nuts (2) and retainer (1).




23. Install and position the clutch cable bracket and cable.
24. Install the clutch cable bracket bolts and washers.

Tighten the bolts to 93 Nm (69 lb ft).




25. If equipped with the 6.6L or 7.2L engines and RPOs MK0/ML0/MM7/MNC and MPU, install the clutch cable retainer (3).
26. Install the adjustment rod swivel (1) from the lever.




27. Install and position the clutch cable bracket and cable.
28. Install the clutch cable bracket bolts.

Tighten the bolts to 36 Nm (27 lb ft).




29. If equipped with the 6.6L engine and RPOs MTD/MK8/MK9 and MWW, install the adjustment rod swivel (5) to the lever.
30. Install the clutch cable retainer (1).




31. If equipped with the 6.6L or 7.2L engines and RPOs MUT/MS9/MT3, install and position the clutch cable bracket and cable.
32. Install the clutch cable bracket nuts and washers.

Tighten the nuts to 36 Nm (27 lb ft).

33. Install the adjustment rod swivel (5) to the lever.
34. Install the clutch cable retainer (1).




35. Install and position the clutch cable bracket and cable.
36. Install the clutch cable bracket nuts and washers.

Tighten the nuts to 23 Nm (17 lb ft).




37. If equipped with the 7.2L engine and RPOs MS9/MT3, install the adjustment rod swivel (5) to the lever.
38. Install the clutch cable retainer (1).




39. If equipped with the 6.6L or 7.2L engine, and RPOs M69/MK8/MK9 and MWW, install the clutch return spring to the bracket and cable swivel.




40. If equipped with the 6.6L or 7.2L engine, and RPOs MUT/MS9/MT3/MK0/ML0, install the clutch return spring to the bracket and lever.




41. If equipped with RPOs MWW/MWX, install the clutch return spring to the bracket and fork.
42. Install the transmission air shift harness. Refer to Transmission Air Shift Harness Replacement Transmission Air Shift Harness Replacement.
43. Install the control lever and/or boot. Refer to Control Lever and/or Boot Replacement Control Lever and/or Boot Replacement.
44. Fill the transmission fluid. Refer to Transmission Oil Change Procedure Transmission Oil Change Procedure.




45. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
46. Adjust the clutch cable. Refer to Clutch Control Cable Adjustment (Push Type) Clutch Control Cable Adjustment (Push Type)Clutch Control Cable Adjustment (Pull Type) Clutch Control Cable Adjustment (Pull Type) in Clutch.