REMOVAL & INSTALLATION
Significant equipment is required to remove and install the transmission safely. This includes supports and jacks for the truck, the engine, transfer case (if equipped) and transmission. Be sure all equipment is rated to safely support the weight of the component. Heavy-duty transmissions are a significant load. Scissors-style jacks are recommended for these items.
- Disconnect the battery negative cable(s).
- Place the transmission in NEUTRAL .
- Remove as much of the shift lever assembly as is accessible from inside the truck: knob, boot, shaft, tower, isolator plate, etc. On some models removal of the console and/or floor panel is required.
- Raise and support the vehicle safely.
- Remove the skidplate(s) if fitted.
- Remove any frame crossmembers that may interfere with removal.
- If the transmission is to be rebuilt, drain the oil.
- Matchmark the driveshaft(s) and yokes or flanges for assembly alignment, then disconnect and remove them. On 4x4 vehicles, remove the front driveshaft as well.
- Remove the exhaust system Y-pipe, and then remove any other segments of the system that would interfere with transmission removal.
- Support the engine with a suitable jack device and wooden block.
- Disconnect the backup switch wires.
- Disconnect the speed sensor wires.
- Remove the rear transmission mount hardware, if fitted.
- On 4x4 models, disconnect the transfer case shift linkage at the case. Remove the transfer case shift mechanism from the transmission.
- Support, unbolt and remove the transfer case.
- Support the transmission with a suitable jack and secure it with safety chains.
- Remove the transmission harness from the retaining clips on the transmission shift cover.
- Remove the hardware attaching the transmission mount to the rear crossmember, if one is fitted.
- Remove the clutch slave cylinder splash shield, if fitted.
- Remove the clutch slave cylinder attaching nuts and place it aside.
- Remove the starter motor.
- Remove the transmission splash shield, if fitted.
- Lower the transmission slightly.
- Remove the shift tower and lever assembly, if it wasn't removed before.
- Remove the bolts attaching the transmission to the clutch housing.
- Move the box rearward until the input shaft clears the clutch disc and release bearing.
- Lower the transmission and remove it from the vehicle.
- Reverse the removal procedure. Note the following points.
Apply a light coat of high temperature grease to the moving parts of the clutch and shifter assemblies:
Drive gear splines and pilot bearing hub
- Tighten transmission-to-engine bolts to 80 ft. lbs. (108 Nm).
- Tighten the transfer case-to-transmission nuts: 5 / 16 in. nuts to 22-30 ft. lbs.; 3 / 8 in. nuts to 30 -35 ft. lbs. (41-47 Nm).
- Frame crossmember and skidplate hardware should be torqued to 30 ft. lbs. (41 Nm).