Jeep Wrangler/YJ 1987-1995 Repair Guide

Transmission

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REMOVAL & INSTALLATION



1987-91 Models
  1. Remove the fan shroud.
  2.  
  3. Disconnect the transmission fill tube upper bracket.
  4.  
  5. Raise and support the vehicle on jackstands.
  6.  
  7. Remove the converter housing inspection cover.
  8.  
  9. Remove the fill tube.
  10.  
  11. Remove the starter.
  12.  
  13. Mark the driveshafts for installation.
  14.  
  15. Remove the driveshafts.
  16.  
  17. Disconnect the gearshift and throttle linkages.
  18.  
  19. Disconnect the neutral start switch.
  20.  
  21. Mark the driveplate and converter for realignment.
  22.  
  23. Remove the converter-to-driveplate bolts.
  24.  
  25. Take up the transmission weight with a floor jack. It's a good idea to chain the transmission to the jack.
  26.  
  27. Remove the rear crossmember-to-transmission bolts.
  28.  
  29. Remove the rear crossmember.
  30.  
  31. Lower the transmission slightly and disconnect the fluid cooler lines.
  32.  
  33. Remove the transmission-to-engine bolts.
  34.  
  35. Roll the transmission rearward to clear the crankshaft, lower the jack and remove the unit.
  36.  

To install:
  1. Position the transmission against the engine.
  2.  
  3. Install the transmission-to-engine bolts. Torque the bolts to 28 ft. lbs. (38 Nm).
  4.  
  5. Connect the fluid cooler lines.
  6.  
  7. Install the rear crossmember. Torque the bolts to 30 ft. lbs. (41 Nm).
  8.  
  9. Install the rear crossmember-to-transmission bolts. Torque the bolts to 33 ft. lbs. (45 Nm).
  10.  
  11. Install the converter-to-driveplate bolts. Torque the bolts to 40 ft. lbs. (54 Nm).
  12.  
  13. Connect the neutral start switch.
  14.  
  15. Connect the gearshift and throttle linkages.
  16.  
  17. Install the driveshafts.
  18.  
  19. Install the starter.
  20.  
  21. Install the fill tube.
  22.  
  23. Install the converter housing inspection cover.
  24.  
  25. Lower the vehicle.
  26.  
  27. Connect the transmission fill tube upper bracket.
  28.  
  29. Install the fan shroud.
  30.  

1992-95 Models

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Matchmark the rear driveshaft and yoke for reassembly. Disconnect and remove the rear driveshaft.
  6.  
  7. Remove the torque converter inspection cover.
  8.  
  9. Matchmark the converter driveplate and converter assembly for reassembly.
  10.  
  11. Remove the bolts attaching the torque converter to the flexplate.
  12.  
  13. Support the transmission assembly with a jack.
  14.  
  15. Remove the bolts attaching the rear crossmember to the transmission side rail.
  16.  
  17. Disconnect the exhaust pipe at the catalytic converter.
  18.  
  19. Lower the transmission slightly in order to disconnect the fluid cooler lines.
  20.  
  21. Matchmark the front driveshaft assembly for installation.
  22.  
  23. Disconnect the driveshaft at the transfer case and secure the assembly aside.
  24.  
  25. Disconnect the back-up light switch wire and speedometer cable.
  26.  
  27. Disconnect the transfer case and transmission linkage.
  28.  
  29. Disconnect the vacuum lines and vent hose.
  30.  
  31. Remove the bolts attaching the transmission assembly to the engine.
  32.  
  33. Move the transmission assembly and torque converter rearward to clear the crankshaft.
  34.  
  35. Carefully lower the transmission assembly from the vehicle.
  36.  
  37. Remove the transfer case retaining bolts from the transmission assembly.
  38.  

To install:
  1. If the transmission and transfer case were separated, re-attach them and torque the bolts to 26 ft. lbs. (35 Nm).
  2.  
  3. Carefully raise the transmission into position.
  4.  
  5. Install the bolts attaching the transmission assembly to the engine. Torque the bolts as follows:

    10mm bolts: 25 ft. lbs. (34 Nm)
     
    12mm bolts: 42 ft. lbs. (57 Nm)
     

  6.  
  7. Connect the back-up light switch wire and speedometer cable.
  8.  
  9. Connect the transfer case and transmission linkage.
  10.  
  11. Connect the vacuum lines and the vent hose.
  12.  
  13. Connect the fluid cooler lines.
  14.  
  15. Connect the driveshaft at the transfer case. New strap bolts should be used whenever the driveshaft is disconnected. Torque the strap bolt nuts to 14 ft. lbs (19 Nm); the flange-to-case bolts to 35 ft. lbs. (47 Nm).
  16.  
  17. Install the rear crossmember. Torque the crossmember attaching bolts to 30 ft. lbs. (41 Nm); the transmission-to-crossmember bolts to 33 ft. lbs. (45 Nm).
  18.  
  19. Connect the exhaust pipe at the catalytic converter.
  20.  
  21. Install the bolts attaching the torque converter to the flexplate. Torque the bolts to 40 ft. lbs. (61 Nm).
  22.  
  23. Remove the floor jack.
  24.  
  25. Install the torque converter inspection cover.
  26.  
  27. Install the rear driveshaft. Use new strap bolts. Torque the strap bolt nuts to 14 ft. lbs. (19 Nm) and the flange bolts to 35 ft. lbs. (47 Nm).
  28.  
  29. Lower the vehicle.
  30.  
  31. Connect the negative battery cable.
  32.  

 
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