H3 2006

Transmission Removal & Installation

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  1. Remove the control lever and boot.
  2.  
  3. Drain the transmission fluid if necessary.
  4.  
  5. Remove the transfer case assembly.
  6.  
  7. Using the J 42371 push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the clutch actuator quick connect.
    NOTE
    It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves, only minimal fluid loss may be experienced.



    Click image to see an enlarged view

    Fig. Using the J 42371 push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the clutch actuator quick connect

  8.  
  9. Disconnect the engine wiring harness electrical connector from the backup lamp switch.

    Click image to see an enlarged view

    Fig. Disconnect the engine wiring harness electrical connector (1) from the backup lamp switch (2), and the engine wiring harness clip (3) from the clip bracket

  10.  
  11. Disconnect the engine wiring harness clip from the clip bracket, and position the harness over the transmission.
  12.  
  13. Disconnect the engine wiring harness clip from the clip brackets, and position the harness aside.

    Click image to see an enlarged view

    Fig. Disconnect the engine wiring harness clip (1) from the clip brackets

  14.  
  15. Remove the nuts securing the fuel hose/pipe brackets to the transmission, and position aside.

    Click image to see an enlarged view

    Fig. Remove the nuts securing the fuel hose/pipe brackets to the transmission

  16.  
  17. Support and secure the transmission using a suitable transmission jack.
  18.  
  19. Remove the transmission crossmember.
  20.  
  21. Remove the service slot plug.

    Click image to see an enlarged view

    Fig. Remove the service slot plug (1)

  22.  
  23. Remove the 7 transmission mounting bolts and 2 studded mounting bolts.

    Click image to see an enlarged view

    Fig. Remove the 7 transmission mounting bolts and 2 studded mounting bolts (2)

  24.  
  25. Remove the remaining transmission mounting bolts.
    NOTE
    Do not allow the transmission to hang from the clutch assembly.



    Click image to see an enlarged view

    Fig. Remove the remaining transmission mounting bolts (2)

  26.  
  27. Pull the transmission straight back off the clutch hub splines.
    NOTE
    Ensure clearance is maintained between the transmission and the following:



    The catalytic converter
     
    The clutch assembly
     
    The engine wiring harness
     
    The fuel hose/pipe brackets
     
    The heater pipe
     

  28.  
  29. Using the transmission jack, carefully lower the transmission from the vehicle.
  30.  

To install:


NOTE
Ensure clearance is maintained between the transmission and the following:



The catalytic converter
 
The clutch assembly
 
The engine wiring harness
 
The fuel hose/pipe brackets
 
The heater pipe
 

  1. Using the transmission jack, carefully raise the transmission to the engine.
    NOTE
    Do not allow the transmission to hang from the clutch assembly.

  2.  
  3. Align the transmission with the engine dowels.
  4.  
  5. Install the 2 transmission mounting bolts. Tighten the transmission mounting bolts to 37 ft. lbs. (50 Nm).
    NOTE
    Ensure the studded mounting bolts are located in the correct position. The heater pipe must be secured with the 2 upper mounting bolts.

  6.  
  7. Install the remaining transmission mounting bolts. Tighten the transmission mounting bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the service slot plug.
  10.  
  11. Install the transmission crossmember.
  12.  
  13. Remove the transmission jack from under the vehicle.
  14.  
  15. Install the nuts securing the fuel hose/pipe brackets to the transmission. Tighten the fuel hose/pipe brackets nuts to 15 ft. lbs. (20 Nm).
  16.  
  17. Connect the engine wiring harness clip to the clip brackets.
  18.  
  19. Lay the engine wiring harness over the transmission.
  20.  
  21. Connect the engine wiring harness electrical connector to the backup lamp switch.
  22.  
  23. Connect the engine wiring harness clip to the clip bracket.
    NOTE
    Ensure the clutch hydraulic hose does not come in contact with any sharp or potential hot surfaces.

  24.  
  25. Push the clutch hydraulic hose quick connect fitting into the clutch slave cylinder, until a "click" is heard.
  26.  
  27. Tug gently on the clutch hydraulic hose to ensure proper retention into the clutch slave cylinder.
  28.  
  29. Install the transfer case assembly.
  30.  
  31. Fill the transmission fluid if removed.
  32.  
  33. Install the control lever and boot.
  34.  

 
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