Diesel Data: Automotive Repair

Removal and Installation

1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Drain lubricant from transmission and transfer case.
4. Disconnect 4 wheel drive indicator switch electrical connector from transfer case, and back-up lamp switch electrical connector from transmission.
5. Remove skid plate, if equipped, from frame.
6. Mark front and rear driveshafts for assembly reference, then disconnect driveshafts from transfer case and position aside.
7. Disconnect speedometer cable from transfer case.
8. Remove retaining clips and shift rod from transfer case control lever and shift lever.
9. Disconnect vent hose from transfer case.
10. Remove shift lever from transmission.
11. Support transmission with a suitable jack and remove transmission housing to engine rear support bracket.
12. Raise rear of transmission to relieve weight from crossmember, then remove 2 nuts attaching upper gusset to frame on both sides of frame.
13. Remove lefthand gusset, then the transmission to crossmember support plate attaching bolts.
14. Raise transmission with a suitable jack, then remove support plate to crossmember attaching nuts and bolts. Remove support plate and righthand gusset.
15. Remove crossmember attaching nuts and bolts and the crossmember.
16. Remove heat shield from transfer case.
17. Support transfer case with a suitable jack and remove 6 transfer case to transmission adapter attaching bolts.
18. Slide transfer case rearward and remove from vehicle.
19. Support transmission with a suitable jack and remove transmission to flywheel housing attaching bolts.
20. Slide transmission rearward until input shaft clears clutch housing, then carefully lower transmission from vehicle. It may be necessary to lower engine to provide sufficient clearance.

NOTE: Do not depress clutch pedal with transmission out of vehicle.

21. Reverse procedure to install.