Procedure
PROCEDUREPerform the diagnostic procedures and repairs outlined below for the repair of Input Seal Replacement R380 Transmission
REMOVAL
1. Place vehicle on lift and disconnect battery ground.
2. Remove cigarette lighter.
3. Release transfer case shift lever boot and unscrew shift knob.
4. Unscrew shift knob of transmission and remove shift boot.
5. Loosen shifter bolt and remove shift lever.
6. Remove switch panel cover and four screws securing switch panel.
7. Pull switch panel out, and disconnect multiplugs from switches.
8. Remove switch panel assembly.
9. Open center console lid.
10. Remove screws securing console.
11. Release two clips securing front of console to bracket.
12. Loosen emergency brake lever boot
13. Remove clip and clevis pin holding cable to emergency brake lever (figure 1).
14. Remove "C" clip and cable adjuster.
15. Select low range to prevent gear lever fouling tunnel when removing gearbox.
16. Remove bolt holding gearbox breather tube clip to cylinder block.
17. Remove bolts holding fan shroud to radiator.
18. Remove fan shroud from radiator and lay over fan blades.
19. Raise lift and drain oil from gearbox and transfer box.
20. Disconnect four heated oxygen sensor wiring connectors.
21. Remove two nuts and bolts holding rear exhaust assembly to front.
22. Remove nuts and release front exhaust assembly from manifolds. Discard gaskets.
23. Lower front exhaust assembly, save "donut" gasket between front and rear exhaust assemblies.
24. Release intermediate exhaust pipe from mountings and tie aside.
25. Remove bolts holding clutch slave cylinder (figure 2).
26. Remove slave cylinder and spacer from clutch housing.
27. Mark drive shafts and flanges to aid in reassembly.
28. Disconnect drive shafts from transfer box and tie aside.
29. Remove clamp and disconnect speedometer cable from transfer box
30. Pull emergency brake cable through transmission tunnel.
31. Temporarily support transmission in a way which allows the cross member to be removed and the adapter plate to be fitted to the transmission.
32. Remove nuts and bolts holding transmission cross member to chassis.
33. Remove nuts and bolts holding transmission cross member to transmission.
34. Remove cross member.
35. Attach # LRT-99-007 gearbox support plate to transmission using lower transfer box retaining bolts. Raise jack enough to take the weight off the transmission.
36. Remove temporary support.
37. Lower jack enough to allow transfer box selector lever to clear transmission tunnel opening.
38. Disconnect differential lock switch connectors.
39. Disconnect backup lamp connectors.
40. Remove clips holding gearbox breather tubes to harness.
41. Support engine under oil pan.
CAUTION: Use a wooden block to protect oil pan.
42. Remove bell housing nuts.
43. Remove transmission while making sure that all connections with engine and chassis have been disconnected.
44. Remove transmission and transfer box as a complete assembly from jack and position on secure work bench.
SEAL REPLACEMENT
1. Remove throw out bearing (figure 3).
2. Remove bolt holding spring clip to clutch release lever and remove clip.
3. Remove clutch release lever.
4. Remove "C" clip from release lever pivot post and discard clip.
5. Remove six bolts and front cover of transmission.
6. Remove inner race and oil seal from front cover.
7. Examine seal bore to ensure that no damage has been done during seal removal.
8. Install new seal. Make sure that the seal is installed down to shoulder. Apply Hylogrip 2000 (Loctite(R) 518) around the front cover as shown in figure 4.
9. Install inner race and clips to main transmission case and install front cover. Seal bolts with Loctite(R).
10. Tighten bolts to 22-28 Nm. (16-20 lbf. ft.).
11. Install new "C" clip on release lever pivot post.
12. Reinstall clutch release lever.
13. Reinstall spring clip to clutch release lever and secure with bolt. Tighten to 7-10 Nm. (5-7 lbf. ft.).
14. Install throw out bearing.
INSTALL TRANSMISSION
1. Place transmission and transfer box assembly on adapter plate and secure with bolts.
2. Clean bell housing and engine mating surfaces.
3. Temporarily install shift lever and select gear that will allow input shaft to engage clutch splines.
4. Position and raise transmission jack to install transmission on engine. Take care not to trap wires or pipes between engine and transmission.
5. Install nuts holding transmission on engine. Tighten nuts to 40 Nm. (30 lbf. ft.).
6. Connect back up light switch and differential lock switch connectors.
7. Secure breather tubes to harness with clips.
8. Position temporary support.
9. Remove two bolts holding adapter plate to transmission and remove jack.
10. Apply Loctite 290 to bolts and tighten to 34 Nm. (25 lbf. ft.).
11. Position cross member, loosely install bolts and nuts holding cross member mountings to transmission.
12. Raise transmission align cross member, and loosely install nuts and bolts holding cross member to chassis.
13. Tighten all nuts and bolts.
14. Remove supporting jack from under oil pan.
15. Remove temporary support.
16. Install emergency brake cable through transmission tunnel and install grommet.
17. Connect speed transducer connector to transfer box.
18. Line up marks and install front and rear driveshafts.
19. Clean spacer, clutch slave cylinder, and gearbox matinq surfaces.
20. Position spacer and slave cylinder, and secure with bolts. Tighten to 25 Nm (19 lbf. ft.).
21. Untie rear exhaust and reinstall front exhaust downpipe using new down pipe to manifold gaskets.
22. Tighten nuts to 45 Nm. (33 lbf. ft.).
23. Install exhaust "donut" and reinstall nuts and bolts to flange of rear exhaust assembly.
24. Refill main gear box with ATF and transfer box with gear oil.
25. Lower lift.
26. Reinstall fan shroud to radiator and tighten bolts.
27. Align breather tube clip to cylinder block and tighten bolts.
28. Install emergency brake cable adjuster and secure with "C" clip.
29. Align cable to lever and install clevis pin. Secure with clip.
30. Check emergency brake operation and adjust as necessary.
31. Install upper gear lever and tighten bolt.
32. Install gear selector lever and high/low selector lever boots.
33. Position boot clamp rings and tighten screws.
34. Reinstall sound insulation.
35. Install center console over emergency brake and gear levers. Make sure electrical plugs are installed correctly and wiring is not trapped.
36. Connect cigarette lighter connector.
37. Install emergency brake lever boot
38. Fit console to bracket and install 2 clips.
39. Install screws to secure center console.
40. Close center console lid.
41. Install multiplug on switch panel.
42. Secure switch panel with four screws and install cover.
43. Install rubber mat.
44. Install upper shift lever and secure with bolt.
45. Install shift lever boot
46. Install transfer box lever boot and reinstall shift knob
47. Install cigarette lighter.
48. Reconnect battery negative terminal.
49. Re-code radio.