REMOVAL & INSTALLATION
Place transmission in Neutral. Remove boot retainer screws. Remove bolts holding gearshift lever assembly. Pull gearshift lever assembly out of transfer case adapter (extension housing). Cover opening to keep dirt out.
Disconnect negative battery cable. Raise and support vehicle. Mark driveshaft and rear axle flange for reassembly reference. Disconnect driveshaft at rear axle drive flange.
Pull driveshaft rearward and disconnect from transmission. Install plug in transfer case adapter (extension housing). Disconnect hydraulic line from master cylinder (clutch housing). Plug opening to avoid leaks.
Remove speedometer cable from transfer case adapter (extension housing). Disconnect wiring from starter motor and transmission switch(es). Place jack under engine and wood block under oil pan. On 4WD vehicles, remove transfer case.
Remove starter motor. Place jack under transmission. Remove bolts, lock washers, and flat washers attaching transmission to engine plate. Remove bolts holding transmission mount and damper to crossmember.
Remove crossmember. Lower engine jack. Remove clutch housing from locating dowels. Slide transmission rearward until input shaft spline clears clutch disc. Remove transmission from vehicle.
To install transmission, reverse removal procedure. Be sure to align splines on input shaft with splines in clutch disc.
PRESSURE PLATE & CLUTCH DISC
Remove transmission. Mark pressure plate and flywheel for reassembly reference. Loosen bolts holding pressure plate to flywheel evenly until springs are expanded. Remove pressure plate and clutch disc from flywheel.
Clean pressure plate and flywheel surface with commercial alcohol base solvent. Place clutch disc on flywheel. Align disc center with pilot bearing using old input shaft or clutch pilot shaft. Place pressure plate on flywheel and align marks made during disassembly.
Tighten bolts evenly in clockwise rotation. Tighten every other bolt for first 3 bolts, then skip to fourth bolt, then every other bolt until all 6 bolts are tightened. Remove clutch pilot shaft. Reverse removal procedure to complete installation.
CLUTCH RELEASE BEARING
Remove transmission, bellhousing, and clutch slave cylinder. Bend back 4 plastic retainers on bearing carrier. Remove bearing from carrier.
Using lithium-based grease, fill annular groove of release bearing. Coat inside diameter of bearing with thin film of grease. Push release bearing into carrier. Make sure bearing is aligned with 4 retainers of carrier. Install slave cylinder in housing.
CLUTCH PILOT BEARING
Remove transmission, pressure plate, and clutch disc. Use Slide Hammer (T59L-100-B) and Puller (T58L-101-A) to remove pilot bearing.
Lightly coat crankshaft bore with lithium-based grease. Using Clutch Aligner (T71P-7137-H) and Bearing Driver (T74P-7137-A), install pilot bearing with seal toward transmission. Install clutch disc, pressure plate, and transmission. Use care when installing transmission so that input shaft does not damage pilot bearing.
NOTE: Use Bearing Driver (T74P-7137-C) on 2.3L engine.
Wednesday, January 28th, 2009 AT 10:15 AM