REMOVAL & INSTALLATION FC Series
- Drain the transmission and transfer case.
- Disconnect the linkage at the transmission and transfer case.
- If the truck has a power take-off, disconnect the control cable at the PTO shift lever.
- Matchmark the driveshafts at the transfer case flanges and disconnect them from the transfer case.
- If so equipped, disconnect the PTO driveshaft from the transfer case.
- Disconnect the speedometer cable.
- Disconnect the front and rear handbrake cables at the lever mounted on the frame crossmember.
- Support the engine with a floor jack, positioned from the front of the truck.
- Place a floor jack under the transmission.
- Remove the nuts holding the rear mount to the crossmember.
- Remove the transfer case snubber bolt at the rear crossmember.
- Unbolt the transmission from the bell housing.
- On the FC-150, force the transmission to the right to disengage the clutch control lever tube ball joint.
- Lower the engine and transmission enough so that the transmission/transfer case assembly will slide out from under the truck. Pull the transmission back until it clears the clutch and bell housing, lower the jack and roll it out from under the truck.
- Remove the transfer case rear cover. If the truck is equipped with a PTO, remove the PTO shift unit.
- Remove the cotter pin, nut and washer which hold the transfer case main drive gear on the end of the mainshaft. Remove the drive gear.
- Remove the bolts and separate the transfer case from the transmission.
- Installation is the reverse of removal. Torque the transmission-to-bell housing bolts to 50 ft. lb.; the mounting bolts to 30 ft. lb.
Wagoneer and J-Series Truck Through 19702-WHEEL DRIVE
The following procedure applies to vehicles both with and without overdrive.
- Drain the transmission, and, if equipped, the overdrive unit. Replace the drain plug(s).
- Remove the access cover from the floor.
- Disconnect the shift rods at the control levers.
- Tag the overdrive solenoid wires and disconnect them.
- Matchmark the driveshaft and axle flange. Disconnect the driveshaft at the rear axle and pull it from the transmission or overdrive.
- Disconnect the speedometer cable at the transmission.
- Disconnect the overdrive control cable.
- Remove the nuts and washers from the rubber support at the rear of the overdrive unit. Don't lose the spacers.
- Remove the overdrive governor assembly.
- Place a floor jack under the bell housing and raise the transmission until the mounting bolts in the rubber insulator clear the frame crossmember.
- Support the transmission with a floor jack and safety chain. Remove the transmission-to-bell housing bolts.
- Pull the transmission rearward until the input shaft clears the bell housing. Lower the unit and remove it from the vehicle.
- Installation is the reverse of removal.
The transfer case and the transmission can be removed as an assembly. However, it is recommended that the transfer case be removed separately for ease in handling the transmission. A special tool is needed for this procedure.
- Drain the oil from the transmission and transfer case. Replace the drain plugs.
- Disconnect the front and rear driveshafts from the transfer case.
- Remove the transfer case.
- Remove the transmission access cover from the floor and disconnect the shift rods from the transmission on the 3-speed transmission.
- On the 4-speed transmission, remove the control housing assembly. Place a clean cloth over the hole to prevent dirt from entering.
- Disconnect the speedometer cable.
- Place a jack under the engine. Protect the engine oil pan with a block of wood.
- Place a transmission jack under the transmission and remove the nuts holding the rear mounting to the frame crossmember.
- Remove the bolts holding the transmission to the flywheel housing or adapter plate.
- Slide the transmission assembly toward the rear of the vehicle until the main drive gear shaft (transmission input shaft) clears the flywheel housing.
- Lower the transmission on the jack and remove the transmission from under the vehicle.
Install the manual transmission in the reverse order of removal, taking note of the following, concerning the installation of the 4-speed transmission:
- When installing the transmission adapter plate to the clutch housing, always check the alignment of the transmission adapter plate bore with the crankshaft. Attach a dial indicator gauge over the inside circumference of the clutch pressure plate and rotate the crankshaft slowly, noting the dial gauge reading. The maximum runout is 0.005 in. If the dial gauge reading is more than this, loosen and reposition the adapter plate as necessary until the correct alignment is obtained.
- When installing the rear adapter plate, be sure that the capscrew heads do not protrude beyond the adapter plate face or interfere with the transfer case fitting tightly against the rear of the adapter plate.
Jeepster/Commando Through 1970
- Drain the lubricant from the transmission and transfer case. Replace the drain plugs.
- Remove the right front seat, floor mat and floor board center section.
- Disconnect the wires from the backup light switch.
- Remove the capscrews securing the cane shift lever housing, then remove the shift lever and shift housing assembly and its gasket from the transmission. Cover the transmission opening with a clean cloth to keep out dirt.
- On vehicles equipped with the remote control console shift lever, disconnect the remote control rods from the transmission shift shaft arm levers.
- Remove the cotter pins and clevis pins securing the transfer shift rods to the control rods of the transfer case.
- Remove the capscrews securing the transfer shift mechanism tube to the support shaft and remove the transfer shift mechanism assembly.
- Remove the skid plate.
- Disconnect the speedometer cable from the transfer case connection.
- Disconnect the parking brake linkage at the bellcrank arm located directly under the transfer case.
- Disconnect the rear driveshaft from the transfer case drive flange, slide the driveshaft yoke rearward, and tie the shaft to one side.
- Disconnect the front driveshaft at the axle.
- On vehicles equipped with the V6 engine, remove the intermediate shaft support bearing cap after the transfer case is out of the vehicle.
- Disconnect the clutch release cable from the clutch cross-shaft assembly.
- Place a jack under the engine, protecting the oil pan with a block of wood.
- Remove the capscrews and insulators securing the transmission stabilizer bracket to the frame. Note the sequence of removal to facilitate installation.
- Remove the nuts and washer securing the frame crossmember to the transmission mount. Lower the frame crossmember and slide the crossmember with the parking brake mechanism attached, forward and out of the way.
- Place a transmission jack under the transmission and transfer case.
- Remove the capscrew and lockwasher securing the stabilizer bracket to the transfer case and remove the stabilizer bracket.
- Remove the bolts and lockwashers securing the transmission case to the flywheel bellhousing adapter.
- Carefully move the transmission and transfer case assembly slightly to the right and remove the clutch control cross-shaft assembly from the frame and transfer case.
- Slide the transmission and transfer case assembly rearward until the transmission main driveshaft is clear of the clutch and bellhousing.
- Lower the transmission jack and remove the transmission case as an assembly from under the vehicle.
- Remove the intermediate shaft support bearing cap from the transfer case.
- Install the transmission in the reverse order of the removal procedure.
1971-73 Jeepster/Commando and 1971-83 Wagoneer, Cherokee, J-Series Truck
- Remove the floor lever knobs, trim rings and boots.
- On 3-speed models, remove the floor covering. Remove the floor pan section from above the transmission. Remove the transmission shift control and lever assembly from the transmission.
- On 4-speed models, remove the shift control housing cap, washer, spring, shift lever and pin.
- Remove the transfer case shift lever and bracket assembly.
- Raise the vehicle.
- Mark the driveshafts and flanges for assembly alignment. Remove the front driveshaft. Disconnect the front end of the rear driveshaft from the transfer case.
- Disconnect the clutch cable and remove the cable mounting bracket from the transfer case.
- Disconnect the speedometer cable, backup light switch wires, transmission control spark advance (TCS), if so equipped, and the parking brake cable if it is connected to the crossmember.
- On 1979 and later models, lower the exhaust system to clear the catalytic converter from the work area.
- Support the transmission with a transmission jack.
- Disconnect the support crossmember from the side sill.
- Remove the bolts which attach the transmission to the clutch housing.
- Lower the transmission slightly. Move the transmission, transfer case and crossmember backward far enough for the transmission clutch shaft to clear the clutch housing.
- Remove the assembly from the vehicle.
- Install the transmission in the reverse order of the removal procedure.
Most transmissions do not have adjustable linkage.
See Figure 1
- Disconnect the control rods at the shift levers.
- Check that the nut on the bolt, passing through the gear shift base, is securely tightened.
- Run the hand lever through its shift pattern to make certain that the response is smooth and positive.
Excessive wear of parts within the shift tower may cause erratic shifting, shifting into two gears at once, or shifting out of a gear position while the gear is still engaged. When these conditions occur, correction may be made by use of one or more spacers, original part number 640778, between the control lever and housing on one or both sides as necessary, as shown at point A in the illustration.
- Check for interference, on FC-170 models, between the fan and the low/reverse lever. This is most likely to occur on models with serial numbers lower than 61568-17645 or 61568-13-10388. A later design control lever was used to correct this.
- Reconnect the control rods.
- Place the hand shifter in NEUTRAL and loosen the jam nut at the rear end of each control rod.
- Remove the cotter keys and remove the control rods from the transmission shift levers.
- With the transmission levers still in Neutral, adjust the length of the control rods so that they slip easily into the holes in the shift levers. Replace the cotter keys and tighten the jam nuts.
- If the first-second shift is difficult, lengthen the low/reverse control rod at the transmission end, by turning the adjusting nut two or three turns at a time until the condition is corrected.
- Loosen the selector arm-to-control rod bolt, at the rear of the control rod.
- Place the hand shift lever in NEUTRAL and slide it right to a position between the third and fourth gear positions. Spring pressure can be felt at this point. Center the lever, fore and aft.
- Place the transmission lever in the NEUTRAL position. In this position, the slots in all the shift rails will be aligned vertically.
- With everything properly positioned, move the selector arm to the center of the slot in the center rail end. Tighten the selector arm bolt.
- Check the shift mechanism for smooth operation.
- If any difficulty in shifting is encountered, check the alignment of the ball pivot shaft, mounted on the transmission, and the end of the control rod. The ball pivot can be adjusted by loosening the attaching bolts.
Wagoneer, Cherokee and J-Series Truck with External Linkage
See Figure 2
- If shifting action is not smooth and positive, first disconnect the transmission shift rods from the remote control levers at the lower end of the steering column.
- Check and correct any binding of the remote control shaft in the steering column.
- Reconnect the rods to the levers at the lower end of the steering column.
- Shift the transmission into Neutral.
- Free the shift rods in the swivel blocks on the transmission shift levers by loosening the locknuts and lock clips. Insert a piece of snug-fitting 3 / 16 in. rod through the remote control shift levers and housing at the lower end of the steering column. Make sure that the transmission gears are in Neutral. The gears are in Neutral when the two shift levers on the side of the transmission are in such a position that either of the levers can be moved freely while the other remains stationary.
- With the 3 / 16 in. rod in place in the remote control shift levers and housing at the lower end of the steering column, tighten the lock clips with the locknuts at the shift levers on the transmission.
- Remove the 3 / 16 in. rod.
See Figure 3
- Remove the button plug from the left side of the console.
- Reach through the hole in the console, lift the shift tower rubber cover and remove the button plug in the shift tower.
- Move the gearshift lever to Neutral.
- Insert a 5 / 16 in. diameter rod through the holes in the console and shift tower and through the aligning holes in the two shift levers.
- Loosen the nut on each of the shift lever adjustments at the transmission. This will free the outer shift levers to move in the elongated holes on the inner shift levers. Make sure the transmission shift levers are in Neutral. Then tighten the nuts to 15-20 ft. lb. torque.
- Remove the 5 / 16 in. diameter aligning rod. Operate the gearshift lever to be sure the transmission detents are engaging in their respective positions.
- Install the button plugs.