Manual Transmission Assembly

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable. Wait at least 90 seconds to perform any work on models equipped with air bags.

   CAUTION
   Some models covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Section 6.

2. Drain the transmission fluid.
3. Raise the vehicle and support safely.
4. Remove the starter motor. Matchmark the driveshafts-to-flange and remove the front (4WD) and rear driveshafts.

   Fig. 2: On the 4WD models, remove the front propeller shaft bracket

5. Remove the clutch release cylinder, hose and bracket.

   Fig. 3: Disconnect the hose and unbolt the slave cylinder from the transmission

6. Remove the exhaust pipe bracket which is retained by four bolts.

   Fig. 4: There are four bolts holding the exhaust pipe bracket to the manual transmission

7. Disconnect the control cables/bracket and speed sensor wiring.

   Fig. 5: Remove the control cable bracket held in by two bolts

8. Remove the engine-to-transmission stiffener plate.

   Fig. 6: Unbolt and lower the stiffener plate

9. Place a suitable transmission jack under the transmission.
10. Remove the engine rear mounting bolts and raise the rear side of the engine.
11. Remove the engine-to-transmission bolts, pull the transmission toward the rear and extract.

    To install:

12. Align the input shaft with the clutch disc and push the transmission fully into position.
13. Install the transmission bolts and tighten to 53 ft. lbs. (72 Nm).
14. Install the rear engine mounts and stiffener plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
15. Connect the speed sensor and control cables.
16. Install the exhaust pipe bracket and tighten to 37 ft. lbs. (51 Nm).
17. Install the clutch release cylinder, starter and driveshafts. Tighten the starter to 41 ft. lbs. (56 Nm) and driveshaft bolts to 20 ft. lbs. (25 Nm).
18. Lower the vehicle.
19. Connect the battery cable and refill with transmission fluid.