REMOVAL & INSTALLATION
Except Standard 4-Speed Transmissions
This procedure is applicable to all 3-speed and overdrive-equipped 4-speed transmissions.
- On 3-speed transmissions, remove the screws (4) that mount the shift lever boot to the floor. Remove the bolts (2) that fasten the gear shift lever to the gear shift control.
- On 4-speed overdrive transmissions, remove the screws that hold the shift lever boot to the floor. Slide the boot up the shifter shaft. Place the shift lever in Neutral and remove the bolts (3) that attach the shift tower to the transmission. Remove the shift lever.
- Disconnect the negative (ground) cable from the battery. Raise the car and support it on jackstands.
- Mark the driveshaft and drive flange on the differential so that the driveshaft may be reinstalled in its original position.
- Disconnect the driveshaft at the differential and slide the front of the shaft out of the transmission extension housing. Seal the rear of the extension housing with a plastic bar, or something similar, to prevent lubricant from leaking out of the transmission.
If you are going to do any repairs to the transmission, drain the lubricant before transmission removal.
- Remove the bolt and retainer securing the speedometer cable and casing to the extension housing and remove the cable.
- On 3-speed transmissions, disconnect the gear shift linkage from the shift control (2 nuts) and remove the shift control from the extension housing (3 bolts). Remove the cotter pins that retain the linkage to the shift levers and remove the linkage.
- Remove the bolts holding the transmission to the rear support. Raise the rear of the engine enough to clear the rear crossmember. Remove the rear crossmember.
- Support the transmission and remove the transmission mounting bolts (4). Pull the transmission to the rear until the input shaft clears the flywheel housing.
- Lower the transmission to the floor.
Do not depress the clutch pedal while the transmission is removed.
- Make sure the mating surfaces of the transmission case and the flywheel housing are clean.
- Start the input shaft through the throwout bearing and line up the splines on the input shaft to those on the clutch disc.
Do not allow the transmission to hang on the input shaft.
- Slide the transmission forward until the input shaft enters the bushing on the crankshaft and the case is against the flywheel housing. It may be necessary to wiggle the transmission slightly.
- When the transmission is snugly against the flywheel housin, and the mounting holes lined up, install and tighten the mounting bolts.
- Raise the engine slightly and install the rear crossmember. Lower the engine, install and tighten the rear support bolts/nuts.
- On three speed transmissions; install the shift linkage, shift control, and adjust linkage. On all transmissions, install the speedometer cable.
- Remove the plastic bag and install the driveshaft; make sure to line up the marks.
- Check the lubricant, add if necessary.
- Lower car, connect the negative battery cable and install the shift lever (four speed).
- Place the gear shift lever in Neutral position.
- Remove the attaching screws at rear of coin tray and lift to release from front hold-down notch on boot retainer. Lift it over the gear shift lever boot.
- Remove the four capscrews attaching the boot to the floor pan and move the boot upward out of the way.
- Remove the three lever attaching bolts.
The attaching bolts are Metric (M8).
Remove the lever and boot assembly from the extension housing.
- Remove the gear shift knob and locknut and slide the boot off the lever.
- Working from under the hood, disconnect the negative (ground) cable from the battery. Remove upper bolts (or stud nuts) that attach flywheel housing to engine.
- Raise the vehicle and support on jackstands.
- Mark the position of the driveshaft relative to the axle companion flange. Remove the driveshaft and seal the extension housing with a plastic bag or equivalent to prevent lubricant leakage.
- Remove the clutch release lever dust cover.
- Disconnect the clutch release cable from the release lever.
- Remove the starter motor attaching bolts and place the starter to one side.
- Remove the speedometer cable attaching screw and lift the cable from the extension housing.
- Support the rear of the engine with a jack and remove the bolts that attach the crossmember to the body.
- Remove the bolt (or bolts) that attaches crossmember to extension housing, and remove the crossmember.
- Lower the engine as required to permit removal of bolts that attach the flywheel housing to the engine. Slide the transmission away from the engine and from under the vehicle.
It may be necessary to slide the mounting bracket forward from the catalytic converter heat shield in order to move the transmission rearward far enough to remove it.
- Remove the cover attaching bolts and drain the lubricant into a container.
- Remove the bolts that attach flywheel housing to transmission case and remove the housing.
- Install a new shift rod seal in the flywheel housing (if the old seal is damaged).
- Position flywheel housing on transmission case, and install and tighten the attaching bolts to specification.
- Install the clutch release lever and bearing.
- Make certain that machined surfaces of flywheel housing and engine are free of dirt and foreign material.
- Apply lubricant to the input shaft bearing retainer. Position the flywheel housing and transmission assembly on the engine block.
It may be necessary to place the transmission in gear and rotate the output shaft to align the input shaft and clutch splines.
- Slide the flywheel housing firmly and squarely onto the locating dowels, to be sure of a positive engagement. Then, holding the flywheel housing firmly in position on the dowels, thread the attaching bolts through the hollow portion of the dowels and into the housing. Tighten the bolts to specification.
- Install and tighten the center attaching bolts.
- Lower the vehicle and install the two upper attaching bolts or stud nuts. Tighten to specification.
- Make sure the shift lever insulator is in a straight downward position on the shift rail.
- Position the shift lever in the extension housing so that the forked ends engage in the insulator properly.
- Install the three metric attaching bolts (M8) and tighten to specifications.
- Slide the boot over the lever and install the attaching bolts. Tighten the bolts to specifications.
- Install the gear shift knob and adjust as shown in the illustrations.
- Position the coin tray over the shift lever boot.
- Secure the tray to front notch on boot retaining ring and attach at rear with screws.
- Raise the vehicle. Raise the engine until the transmission reaches its normal position. Secure the crossmember to the body with the attaching bolts, and tighten to specification. Install the bolt that attaches crossmember to extension housing, and tighten to specification.
- Position the catalytic converter heat shield mounting bracket to the transmission mount.
- Remove the plastic bag, install the speedometer cable and tighten the attaching screw.
- Position the starter, install the attaching bolts.
- Apply grease to the ball end of the clutch release cable and connect it to the release lever. Install the clutch release fork dust cover.
- Install the driveshaft, making sure that it is connected to the pinion flange in its original position.
- Fill the transmission with the specified lubricant until it appears at the bottom of the filler plug hole. Install the filler plug.
- Install the backup lamp switch and connect the wire to the switch.
- Lower the vehicle to the ground. Install and tighten the upper flywheel housing mounting bolts. Connect the negative battery cable.
- Check the transmission for proper operation.