REMOVAL & INSTALLATION
See Figures 1, 2 and 3
Remove the shift lever boot and the shift lever prior to transmission removal.
- Disconnect the negative battery cable.
- Raise the vehicle and support it safely with jackstands.
- For 1996-98 5-speed transmissions, disconnect the clutch actuator line from the actuator.
- Position a suitable pan under the vehicle, then drain the lubricant from the transmission.
- Support the rear axle with a suitable jackstand.
- Mark the driveshaft and the rear axle pinion flange to indicate their relationship. Unbolt the rear universal joint straps. Lower the rear of the driveshaft, being careful to keep the universal joint caps in place. Withdraw the driveshaft from the transmission and remove it from the vehicle.
- Remove the rear axle torque arm from the vehicle. For details, refer to Suspension & Steering of this repair guide.
- Remove the catalytic converter hanger.
- For the 5-speed transmission, detach the electrical connectors from the back-up light switch and the speed sensor.
- For the 6-speed transmission, unplug the electrical connectors from the reverse lockout solenoid, skip shift solenoid and back-up light switch.
For the 6-speed transmission, perform the following:
- Remove the actuator cylinder nuts.
Disconnect the clutch master cylinder pushrod before disconnecting the actuator cylinder. If not disconnected, permanent damage to the actuator cylinder will occur if the clutch pedal is depressed while the actuator is disconnected.
- Remove the clutch actuator cylinder and secure with a piece of wire. Do NOT let the cylinder hang by its hydraulic fluid line!
- Remove the actuator spacer.
- Pull the clutch fork down to disengage it from the release bearing. The fork MUST be detached from the release bearing to prevent damage to the clutch system.
- Detach the electrical connector from the electronic speed sensor.
- Support the engine with a suitable jackstand. Support the transmission with a jackstand.
Remove the transmission support and transmission mount, as follows:
- Remove the transmission mount nut and washer from the transmission mount,
- Remove the transmission support bolts/screws from the rail.
- Remove the transmission support.
- Remove the transmission mount bolts/screws from the manual transmission, then remove the mount.
- With the help of an assistant, carefully lower the transmission enough to reach the transmission control assembly bolts/screws.
- Carefully lower the transmission, then remove the transmission control assembly.
- Unfasten the transmission retaining bolts/screws. With the help of an assistant, remove the transmission assembly from the flywheel. Place the transmission in a suitable holding fixture.
- Installation is the reverse of the removal procedure. Please note the following important steps:
- When installing the transmission to the flywheel housing, position the pilot splined input shaft into the clutch disc hub and pilot bearing.
- For the 5-speed manual transmission, tighten the transmission mounting bolts/screws to 55 ft. lbs. (75 Nm) and the transmission control assembly bolts/screws to 15 ft. lbs. (20 Nm).
- For the 6-speed manual transmission, tighten the transmission mounting bolts/screws to 26 ft. lbs. (35 Nm). Tighten the actuator cylinder nuts to 15 ft. lbs. (25 Nm).
- When connecting the actuator line, make sure it is not twisted or kinked and will not rub against any other components. Also, the quick-connect fitting must be pushed on, then pulled back to be sure of proper engagement.
- Fill the transmission with the proper type and amount of fluid. If any hydraulic clutch components were removed, bleed the clutch system.