REMOVAL & INSTALLATION
Two Wheel Drive
- Raise the vehicle and support it on jack stands.
- Drain the transmission.
- Disconnect the speedometer cable, TCS switch and backup light wire at the transmission.
- Disconnect the shift control rods from the three speed transmission. On four speeds, pull up the boot and remove the gearshift lever. This can be done by pressing down firmly on the slotted collar plate with a pair of channel lock pliers and turning counterclockwise to release the lever. Plug the opening to keep out dirt.
- Remove the power take-off unit, if any.
- Remove the driveshaft after marking the alignment of the shaft to the flange.
- Position a jack under the transmission to support the weight of the transmission.
- Remove the crossmember. Visually inspect to see if other equipment, brackets or lines, must be removed to permit removal of the transmission.
Mark the position of the crossmember when removing to prevent incorrect installation. The tapered surface should face the rear.
- On models through 1977, remove the flywheel housing underpan.
- Remove the top two transmission to housing bolts and insert two guide pins.
Guide pins are nice to have but aren't absolutely necessary. If you choose to go on without them, be very careful when removing the transmission. The use of guide pins will not only support the transmission but will prevent damage to the clutch disc. Guide pins can be made by taking two bolts, the same as those just removed only longer, and cutting off the heads. The pins can be installed with your hands. If they're difficult to turn, use locking pliers. Be sure to support the clutch release bearing and support assembly during removal of the transmission. This will prevent the release bearing from falling out of the flywheel housing.
- Remove the two remaining bolts and slide the transmission straight back from the engine. Use care to keep the transmission drive gear straight in line with the clutch disc hub.
- When the transmission is free from the engine, move it from under the vehicle.
- Place the transmission on the guide pins and slide it forward starting the main drive gear into the clutch disc's splines.
Place the transmission in gear and rotate the transmission flange or output yoke to aid entry of the main drive gear into the disc's splines. Make sure the clutch release bearing is in position.
- Install the two lower transmission mounting bolts, and the flywheel lower pan (if equipped).
- Remove the guide pins and install the upper mounting bolts. Torque to 55 ft. lbs. on models through 1972, and to 75 ft. lbs. for 1973-82 models. Replace the crossmember.
- Install the driveshaft, watching the alignment marks.
- Connect the backup light switch and TCS switch (if used).
- Connect the shift levers, or install the lever. Use the procedure in Step 4 to install the four speed shift lever, turning clockwise.
- Connect the speedometer cable and refill the transmission.
- Lower the vehicle.
- Jack up the vehicle and support it safely on stands. Remove the skid plate, if any.
- Drain the transmission and transfer case. Remove the speedometer cable and the TCS switch from the side of the transmission.
- Disconnect the driveshafts at the transmission and transfer case and secure them out of the way.
- Remove the transfer case shifter lever by removing the bolt to the adapter assembly. You can then push the shifter aside and hang it out of the way with rope or wire.
- On models through 1977, support the transfer case and remove the adapter attaching bolts. On 1978 and later models, remove the bolts attaching the strut to the right side of the transfer case and the rear part of the engine and remove the strut.
- Remove the transfer case securing bolts from the frame and lower and remove the transfer case. (The case is attached at the right side of the frame.)
- Disconnect the shift rods from the transmission.
- While supporting the rear of the engine, remove the adapter mounting bolts.
- Remove the upper transmission bolts and insert two guide pins to keep the assembly aligned. See the two wheel drive procedure (Step 10) for details on making these.
- Remove the flywheel pan and the lower transmission-to-clutch housing bolts.
- Pull the transmission and the adapter straight back on the guide pins until the input shaft is free of the clutch disc.
- The transmission and the adapter are removed as on assembly. The adapter can be separated once the assembly is out.
- Installation is the reverse of removal. Place the transmission in gear and turn the output shaft to align the clutch splines. Transmission bolt torque is 55 ft. lbs. on models through 1972, and 75 ft. lbs. for 1973-82 models. Refer to the transfer case removal and installation procedure for adapter bolt torques.
- Remove the shifter boots and the floor mat or carpeting from the front passenger compartment.
- Remove the transmission shift lever. See the two wheel drive procedure, Step 4, for details on removing the lever. Remove the console box and the center floor heater outlet.
- Remove the transmission floor cover after releasing the attaching screws. It will be necessary to rotate the cover 90° to clear the transfer case shift lever.
- Remove the skid plate, if any. Disconnect the transfer case shift lever link assembly and the lever from the adapter.
- Remove the back-up light wire, the TCS switch, and the speedometer cable from the side of the transmission.
- Raise and support the truck. Support the engine. Drain the transmission and transfer case. Detach both drive shafts and secure them out of the way.
- Remove the transmission mount-to-frame bolts. To do this, it will be necessary to open the locking tabs. Remove the transfer case-to-frame bracket bolts.
- While supporting the transmission and transfer case, remove the crossmember bolts and the crossmember. It will be necessary to rotate the crossmember to remove it from the frame.
- Remove the lower flywheel housing cover.
On V8 engines it is necessary to remove the exhaust crossover pipe.
- Remove the transmission-to-bellhousing bolts. Remove the upper bolts first and install guide pins. Refer to the two wheel drive procedure for details on making these.
- Slide the transmission back until the main drive gear clears the clutch assembly and then lower the unit.
- Install the transfer case on the transmission as an assembly. Attach the assembly to the bellhousing. Put the transmission in gear and turn the output shaft to align the clutch splines.
- Install the bellhousing cover and, on V8 models, the exhaust crossover pipe.
- Install the frame crossmember, the retaining adapter, and the transfer case.
- Install the front and rear driveshafts.
- Connect the speedometer cable, backup lights, and TCS switches.
- Fill the transmission and the transfer case to the proper level with the specified lubricant. Refer to for this procedure.
- Position the transfer case shift lever and the shift lever link on the shift rail bar.
- Install the transmission floor cover and the center heating duct.
- Install the console box.
- Install the transmission shift lever. Refer to the three speed procedure. Step 13, for bolt torques.