REMOVAL & INSTALLATION
- Disconnect the negative battery cable for safety purposes.
- Remove the gearshift handle.
- Firmly set the parking brake and block the drive wheels, then raise and support the front of the vehicle safely using jackstands.
- Drain the transmission fluid.
- Matchmark the driveshaft for reassembly. Disconnect the driveshaft from the rear U-joint flange. Slide the driveshaft off the transmission output shaft, then install an extension housing seal installation tool into the extension housing to prevent residual lubricant from leaking.
If a seal tool is not available, place a plastic bag over the extension housing and secure it with one or more rubber bands. This will help prevent a mess of transmission fluid.
- Remove the mounting fasteners, then remove the dual catalytic converter Y-pipe from the vehicle.
- Remove the retaining bolt and the clutch release lever dust shield, then disconnect the clutch cable.
- Remove the two nuts attaching the rear transmission support to the crossmember, then remove the retaining bolts.
- Use a floor jack to support the engine and transmission assembly. Always use a block of wood between the engine/transmission and the floor jack to spread the load, and to prevent damage to the engine and drive train components.
- Remove the two nuts from the crossmember bolts. Remove the bolts, then use the jack to raise the transmission slightly and remove the crossmember.
- Disengage the wiring harness connectors from the back-up lamp switch and the Vehicle Speed Sensor (VSS). On the 5.0L engine, disconnect the Neutral sensing switch.
- If equipped, remove the bolt from the speedometer cable retainer, then remove the speedometer driven gear from the transmission.
- Remove the starter motor.
- Position a jackstand under the back of the engine to support it while the transmission is removed from the vehicle.
- Remove the transmission-to-flywheel housing retaining bolts.
- Remove the transmission and jack rearward until the transmission input shaft clears the flywheel housing. If necessary, lower it enough to obtain clearance for removing the transmission.
Installation is the reverse of the removal procedure. Please note the following important steps:
- Make sure the mounting surface of the transmission and flywheel housing are clean and free of dirt, paint and burrs.
- Install two guide pins in the flywheel housing lower mounting bolt holes. Raise the transmission, then move it forward onto the guide pins until the input shaft splines enter the clutch hub splines and the case is positioned against the flywheel housing.
- Tighten the transmission-to-flywheel retaining bolts to 28-38 ft. lbs. (38-52 Nm) for the T45 transmission, or to 45-64 ft. lbs. (61-88 Nm) for the T50D transmission.
- Tighten the transmission support attaching bolts to 36-50 ft. lbs. (48-68 Nm).
- Tighten the extension housing support retaining nut to 25-35 ft. lbs. (34-48 Nm).
- Tighten the catalytic converter Y-pipe attaching fasteners to 20-30 ft. lbs. (27-41 Nm).
- Before starting the engine, be sure to install the transmission drain plug, fill the transmission with 5.6 pts. (for the T50D), or with 6.4-6.7 pts. (for the T45) of Mercon ® multi-purpose automatic transmission fluid, and to install the transmission fluid fill plug. Use a pipe sealant with Teflon®on the drain and fill plugs, and tighten them to 13-21 ft. lbs. (17-29 Nm).
- After installing the shift handle, check the shift and crossover motion for full shift engagement and smooth crossover operation.
Remember to remove the wheel blocks before attempting to move the vehicle.