Transmission

Tools Required:

• Extension Housing Seal Replacer T74P-77052-A

Removal

1. Disconnect the battery negative cable.

2. Raise the vehicle on a hoist. Refer to Section 00-02.

3. Place a drain pan under the transmission fluid pan. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow the fluid to drain. Then remove all of the pan attaching bolts except two at the front, to allow the fluid to further drain. After all the fluid has drained, install two bolts on the rear side of the pan to temporarily hold it in place.

4. Remove the converter access cover and adapter plate bolts from the engine oil pan.

    CAUTION: Care should be taken not to damage cooler lines.

    CAUTION: Never rotate the crankshaft pulley in a counterclockwise direction (as viewed from the front).

5. Remove the four flywheel-to-converter attaching nuts by placing a 22mm socket and breaker bar on the crankshaft pulley attaching bolt. Rotate the pulley clockwise (as viewed from front) to gain access to each of the nuts.

6. Scribe a mark indexing the driveshaft to the rear axle flange. Remove the driveshaft (refer to Section 05-00) and install a spare slip yoke or Extension Housing Seal Replacer T74P-77052-A in the extension housing.

7. Disconnect and remove the speedometer sensor from the extension housing.
   
   
   
   

8. Disconnect the shift rod at the transmission manual lever. Disconnect downshift linkage at transmission downshift lever. Depress the tab on the downshift linkage retainer and remove the linkage from the bracket.

9. Remove starter-to-converter housing attaching bolts and position starter out of the way.

10. Disconnect the park/neutral position switch wires and the torque converter clutch/3-4 shift solenoid connector.
    
    
    
    

11. Remove the vacuum hose from the transmission vacuum modulator.
    
    
    
    

12. Position a transmission jack under the transmission and raise it slightly.

13. Remove the engine rear support-to-crossmember bolts.

14. Remove the crossmember-to-frame side support attaching bolts and remove the crossmember insulator and support and damper.
    
    
    
    

15. Lower the jack under the transmission and allow the transmission to hang.

16. Position a jack to the front of the engine and raise the engine to gain access to the two upper converter housing-to-engine attaching bolts.

17. Disconnect the oil cooler lines at the transmission. Plug all openings to keep out dirt.

18. Remove the lower converter housing-to-engine attaching bolts.

19. Remove the transmission oil filler tube.
    
    
    
    

20. Secure the transmission to the jack with a safety chain.

21. Remove the two upper converter housing-to-engine attaching bolts. Move the transmission to the rear so it disengages from the dowel pins and the converter is disengaged from the flywheel. Lower the transmission from the vehicle.
    
    
    
    

    NOTE: If the transmission is to be removed for a period of time, support the engine with a safety stand and wood block.

22. Remove torque converter from transmission.
    
    
    
    

Installation

1. Proper installation of the converter requires full engagement of the converter hub in the pump gear. To accomplish this, the converter must be pushed and at the same time rotated through what feels like two "notches" or bumps. When fully installed, rotation of the converter will usually result in a clicking noise heard, caused by the converter surface touching the housing-to-case bolts. This should not be a concern but rather an indication of proper converter installation since, when the converter is attached to the engine flywheel, it will be pulled slightly forward, away from the bolt heads. Besides the clicking sound, the converter should rotate freely with no binding.

   For reference, a properly installed converter will have a "dimension A" converter pilot nose from face to converter housing outer face of 10.23mm (7/16 inch) minimum to 14.43mm (9/16 inch) maximum.
   
   
   
   

2. With converter properly installed, place transmission on jack and secure with safety chain.

3. Rotate the converter so the drive studs are in alignment with their holes in the flywheel.

    CAUTION: During this move, to avoid damage, do not allow the transmission to get into a nose down position as this will cause the converter to move forward and disengage from the pump gear. The converter housing is piloted into position by dowels in the rear of the engine block. The converter must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.

4. With the transmission mounted on a transmission jack, move the converter and transmission assembly forward into position being careful not to damage the flywheel and the converter pilot.

5. Install two converter housing-to-engine attaching bolts at the engine dowel locations. Tighten to 38-51 Nm (28-38 lb-ft).

6. Install the remaining converter housing-to-engine attaching bolts and tighten to 38-51 Nm (28-38 lb-ft).

7. Remove the safety chain from the transmission.

8. Install the oil filler tube and secure it to the cylinder block with the attaching bolt. Tighten the bolt to 38-51 Nm (28-38 lb-ft). If the oil filler tube is loose in the case it should be replaced.

9. Install the oil cooler lines in the retaining clip at the cylinder block. Connect the lines to the transmission case.

10. Remove the jack supporting the front of the engine.

11. Raise the transmission. Position the crossmember, insulator and support and damper to the frame side supports and install the attaching bolts. Refer to Section 02-03 for torque specifications for the engine in the vehicle.

12. Lower the transmission and install the rear engine support-to-crossmember nut. Refer to Section 02-03 for torque specifications for the engine in the vehicle.

13. Remove the transmission jack.

14. Install the vacuum hose on the transmission vacuum diaphragm. Install the vacuum line into the retaining clip.

15. Connect the park/neutral position switch plug to the switch. Install the torque converter clutch/3-4 shift solenoid connector.
    
    
    
    

16. Install the starter and tighten the attaching bolts to 20-27 Nm (15-20 lb-ft).

17. Install four fly-wheel-to-converter attaching nuts. Tighten to 27-46 Nm (20-34 lb-ft).

18. Install converter access cover and cover plate bolts on engine pan. Tighten to 2.5-3.6 Nm (22-32 lb-in).

19. Connect the muffler inlet pipe to the exhaust manifold.

20. Connect the transmission shift rod to the manual lever.

21. Connect the downshift linkage to the downshift lever.

22. Install the speedometer sensor and connect wiring.

23. Install the driveshaft so the marks scribed on the driveshaft and rear axle flange are in alignment. Tighten the circular companion flange attaching bolts to 95-130 Nm (70-95 lb-ft).

24. Adjust the manual and downshift linkage as required. Refer to Sections 07-05 and 10-02.

25. Remove safety stands and lower the vehicle. Connect the battery negative cable.

26. Pour 4.7L (5 quarts) of specified fluid into dipstick tube. Start engine and add fluid as required to achieve the proper fluid level as specified.

27. Check the transmission, converter assembly and oil cooler lines for leaks.