Diesel Data: Automotive Repair

Removal

WARNING:
- MAKE SURE LIFTS, JACKS AND SAFETY STANDS ARE PLACED PROPERLY, AND HOIST BRACKETS ARE ATTACHED TO THE CORRECT POSITION ON THE ENGINE.
- APPLY PARKING BRAKE AND BLOCK REAR WHEELS SO VEHICLE WILL NOT ROLL OFF STANDS AND FALL ON YOU WHILE WORKING UNDER IT.

CAUTION: Use fender covers to avoid damaging painted surfaces.

NOTE:
The original radio has a coded theft protection circuit. Be sure to get the customer's code number before
- Disconnecting the battery.
- removing the No. 39 (7.5 A) fuse from the under-hood fuse/relay box.
- removing the radio.
- After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.

1. Disconnect the battery negative ( - ) and positive ( + ) cables from the battery.
2. Remove the battery set plate, then remove the battery.





3. Remove the drain plug, and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer. Torque to 49 Nm (36 ft. lbs.)





4. Remove the intake air duct B and intake air duct/air cleaner housing assembly.





5. Disconnect the intake air resonator control solenoid valve connector, then remove the vacuum hoses and intake air resonator.
6. Remove the battery cable and ground cable bracket from the battery base.
7. Remove the battery base.





8. Remove the battery base bracket.
9. Disconnect the transmission ground cable from the transmission.
10. Disconnect the lock-up control solenoid valve and the shift control solenoid valve connectors.
11. Disconnect the throttle control cable from the throttle control lever.
12. Disconnect the mainshaft speed sensor connector.





13. Remove the ATF cooler hoses at the joint pipes. Turn the ends of the ATF cooler hoses up to prevent ATF from flowing out, then plug the joint pipes.

NOTE: Check for any signs of leakage at the hose joints.

14. Remove the starter motor cables.





15. Disconnect the countershaft speed sensor connector.





16. Disconnect the vehicle speed sensor connector.





17. Remove the transmission housing mounting bolts.





18. Loosen the front engine mount bracket bolts.





19. Remove the transmission mount.





20. Remove the splash shield.





21. Remove the center beam.
22. Remove the cotter pins and castle nuts, then separate the ball joints from the lower arm.





23. Remove the damper fork bolts, then separate the damper fork and lower arm.
24. Pry the driveshafts out of the differential.
25. Pull on the inboard joint, and remove the right and left driveshafts.





26. Tie plastic bags over the driveshaft ends.

NOTE: Coat all precision finished surfaces with clean engine oil.

27. Remove the right damper pinch bolt, then separate the damper fork and damper.





28. Remove the self-locking bolts and self-locking nut, then remove the right radius rod.
29. Remove the torque converter cover and shift cable cover.





30. Remove the lock bolt securing the control lever, then remove the shift cable with the control lever.





31. Remove the eight drive plate bolts one at a time while rotating the crankshaft pulley.
32. Place a jack under the transmission, and raise the transmission just enough to take weight off of the mount.
33. Remove the intake manifold bracket.
34. Remove the transmission housing mounting bolts and rear engine mounting bolts.





35. Pull the transmission away from the engine until it clears the 14 mm dowel pins, then lower it on the transmission jack.