Chapter 7 Part A Manual transmission

Contents
General information ........................ _. _ _ _ _ .. _. __ 1 Manual transmission -removal and installation ............... 5
Lubricantchange ............................. SeeChapter Oilseals-replacement .... ____,.__ . _____ _ ._____ __ _.__._ 2 -~~~
Lubricant level check .......................... See Chapter 1 Shift lever - removal and installation ....................... 3
fvlanual transmission overhaul -general information .......... 6 Transmission mount-check and replacement ............... 4

Specifications

General
Lubricanttype . . . . ..__......_..............-...-.....- See Chapter 1

Torque specifications Ft-Lbs

Transmission-to-engine bolts
Four-cylinder engines . . . . . . . . . . . . . . . _ _ . . . . . . . . _ _ _ _ . . . . 40
V6engine . . .._______......._....._.........._._.... 60

1 General information
All vehicles covered in this manual come equipped with either a four-
speed or five-speed manual transmission or an automatic transmission.
All information on the manual transmissions is included in this part of
Chapter 7. Information on the automatic transmission and transfer case
can be found in Parts B and C of this Chapter.
The manual transmission used in these models is a four-speed or a
five-speed unit, with fifth gear being an overdrive.
Due to the complexity, unavailability of replacement parts and the spe-
cial tools necessary, internal repair by the home mechanic is not’recom-
mended. The information in this Chapter is limited to general information
and removal and installation of the transmission.
Depending on the expense involved in having a faulty transmission
overhauled, it may be a good idea to replace the unit with either a new or
rebuilt one. Your local dealer or transmission shop should be able to sup-
ply you with information concerning cost, availability and exchange policy.
Regardless of how you decide to remedy a transmission problem, you can
still save a lot of money by removing and installing the unit yourself.
 Chapter 7 Part A Manual transmission

2wD i 2.13 Exploded view of the speedometer driven gear assembly

EXTENSION HOUSING
i Spring pin 4 O-ring
2.6 A slide hammer with a special seal puller may be 2 Drivengear 5 O-ring
required to remove the oil seal 3 Housing

of these seals is relatively easy, since the repairs can usually be performed
without removing the transmrssion or transfer case (4WD models) from-.-~
the vehicle.
2 The extension housing oil seal is located at the extreme rear of the
transmission or transfer case, where the driveshaft is attached. If leakage
at the seal is suspected, raise the vehicle and support It securely on fack-
stands. ff the seal is leaking, transmission lubricant will be built up on the
front ofthe driveshaft and may be dripping from the rear of the transmis-
sion or transfer case.
3 Refer to Chapter 8 and remove the driveshaft.
4 Using a soft-faced hammer, carefully tap the dust shield (if equipped)-
to the rear and remove it from the transmission. Be careful not to distort it.
5 Using a screwdriver or pry bar, carefully pry the oil seal out of the rear
of the transmission or transfer case. Do not damage the splines on the
transmission output shaft.
6 If the oil seal cannot be removed with a screwdriver or pry bar, a spe-
cial oil seal removal tool (available at auto parts stores) will be required
(see illustration).
7 Using a large section of pipe or a very large deep socket as a drift,
install the new oil seal. Drive it into the bore squarely and make sure it’s_
completely seated.
8 Reinstall the dust shield (if equipped) by carefully tapping it into place.
Lubricatethe splines of the transmission output shaft andthe outside of
the driveshaft sleeve yoke with lightweight grease, then install the drive-
shaft. Be careful not to damage the lip of the new seal.
0 The speedometer gear housing is located on the side of the extension _
housing. Look for transmission lubricant around the housing to determIne-~_
if the O-rings are leaking.
IO Unscrew the speedometer cable casing from the speedometer gear
housing.
11 Mark the relationship of the speedometer gear housing to the exten-
sion housing.
12 Remove the bolt and withdraw the housing.
13 Install a new O-ring on the driven gear shaft and on th-e housing. then T
reinstall the housing (see illustration).

3.3 Shift lever details

3 Shift lever - removal and installation
1 Shift knob 4 Stopper plate
2 Shifter boot p/ate 5 Gasket Refer to illustration 3.3
3 Gasket 6 Shift lever
Removal
1 Disconnect the negative cable from the battery.
2 If your vehicle is equipped with a center console, remove it (see Chap-
2 Oil seals - replacement
ter 11).
3 Removethescrewsthatattachtheshifterbqotplatetothetunnel(see
Refer to illustrations 2.6 and 2,13 illustration). Lift off the plate and pull back the rubber boot.Jt has a lip that
1 Oil leaks frequently occur due to wear of the extension housing oil frts over the sheetmetal of the tunnel; take care not to tear the boot as you _
seal and/or the speedometer drive gear oil seal and O-ring. Repfacement pull it back.
 Chapter 7 Part A Manual transmission

4.3a Transmission mount (2WD models) 4.3b Transmission mount (4WD models)

4 If the transmission is a 5-speed, place the shift lever in the first gear the frame crossmember and pull the speedometer cable away from the
position. If it is a 4-speed, place it in the second gear position. Remove the engine and transmission. Lay it on top of the left frame rail to keep’it out of
three boltsattaching theshiftleverassemblytothetransmissionandcare- the way.
fully lift out the lever. Plug or cover the hole with a clean rag. 7 Push forward on the parking brake lever and disengage the cable
from the lever. Loosen the parking brake cable housing clamp in front of
Installation the frame crossmember and slide the cable housing forward to free it from
5 Apply a thin coat of RTV sealant to both sides of the two gaskets (one the support bracket on the crossmember. Lay the cable on top of the left
over and one under the shift lever stopper plate). frame rail to keep it out of the way. Remove the pin attaching the rear park-
6 Apply multi-purpose grease to the shift lever bushing and all shift le- ing brake cable balancer to the parking brake lever.
ver sliding surfaces. 8 Unplug the electrical connector for the back-up light switch (just be-
7 The remainder of installation is the reverse of removal. Tighten the hind the steering box). Disconnect the clutch cable from the clutch control
fasteners securely. lever at the transmission bellhousing. Back off the clutch cable adjuster
.and put as much freeplay as possible in the cable. Pull the rubberdustcov-
er from the end of the clutch cable and slip the cable through the mounting
4 Transmission mount - check and repl.acement bosson thetransmission bellhousing. Laytheclutchcableon topoftheleft
frame rail to keep it out of the way.
9 Remove the splash shield from the front of the transmission. It is at-
Refer to illustrations 4.3a and 4.3b
tached to the engine with two bolts and to the transmission with two bolts.
Check 10 Remove the bolt attaching the exhaust pipe bracket to the transmis-
1 insert a large screwdriver or pry bar into the space between the trans- sion.
mission extension housing and the crossmember and try to pry up slightly. 11 Support the engine with a hoist or, if a hoist ish’t available, a floorjack
2 The transmission should not move from the crossmember. If there is placed under the engine oil pan (place a wood block on the jack head to
any cracking or separation of the rubber from the mounting plate, replace serve as a cushion). Remove the bolts that attach the transmission bell-
the mount housing to the engine block.
12 Remove the two nuts that attach the transmission to the transmission
Replacement support crossmember.
3 Support the transmission with a jack. Place a block of wood on the 13 Support the transmission with a sturdy jack (preferably one equipped
jack head to serve as a cushion. Remove the fasteners attaching the with wheels or casters). Remove the transmission supportcrossmember.
mount to the crossmember and the transmission (see illustrations). 14 Carefully move the transmission straight back and away from the en-
4 Raise the transmission slightly with the jack and remove the mount: gine by moving the transmission supporting jack toward the rear of the ve-
5 Installation is the reverse of removal. Be sure to tighten the nuts/bolts hicle. It would be very helpful to have an assistant at this point. You must
securely. pull the transmission straight back until it is completely free from the en-
gine or damage to the input shaft may result.
15 Slowly lower the jack and move the transmission out from under the
vehide.
5 Manual transmission - removal and installatjon
Installation
Removal 16 ‘Installation is the reverse of removal. Be sure to check the clutch disc
1 Disconnect the negative battery cable from the battery. to make sure it is centered (see Chapter 8) before sliding the transmission
2 Remove the air cleaner assembly (see Chapter 4), then remove the into place. Also, before installation, apply a coat of lithium-based grease to
starter (see Chapter 5). the end of the transmission input shaft and the splines.
3 Raise the vehicle and support it securely on jackstands. Place a drain 17 With the help of ari assistant, line up the clutch with the transmission
pan under the transmission, remove the drain plug and allow the transmis- input shaft. Make sure the engine and transmission are in a straight line,
sion to lubricant to drain. not angled in relation, to each other. Carefully slide the transmission for-
4 Remove the driveshaft (see Chapter 8). ward until the bellhousing contacts the engine block. To properly engage
5 Remove the shift lever (see Section 3). the clutch disc and the transmission input shaft, you may have to rotate the
6 Disconnect the speedometer cable where it enters the transmission. crankshaft slightly (with a wrench on the bolt holding the pulley to the front
Bend back the retaining strap that holds the speedometer cable housing to of the crankshaft). Do not force the input shaft into the clutch. If the trans-
 Chapter 7 Part A Manual transmission

mission does not move forward smoothly, either the clutch disc/input shaft transmissionsmay beavailable-checkwithyourdealerpartsdepattment
splines are not lined up, or the transmission is cocked at an angle. and auto parts stores. At any rate, the time and money invohedin an ovi%-
18 Once the tratism%G5nisTn place, support it securely and tighten all of haul is almost sure to exceed the cost of a rebuilt unit.
the mounting bolts to the torque listed in this Chapter’s Specifications. Nevertheless, it’s not impossible for an inexperienced mechanic to re-
19 Don’t forgef to fill the transmission to the proper level with the recom- build a transmission if the special tools are available and the job is done
m~%dedtubricant(S@e Chapter 1). in a deliberate step-by-step manner so nothing is overlooked.
20 -Be sure to adjust the clutch as described in Chapter 8. The tools necessary for an overhaul include internal and external
.-. snap-ring pliers, a bearing puller, a slide hammer, a set of pin punches,
a dial indicator and possibly a hydraulic press. In addition, a large, sturdy
workbench and a vise or transmission stand will be required.
6 Manual transmission overhaul - general information During disassembly of the transmission, make careful notes of how
each piece comes off, where it fits in relation to other pieces and what
Refer to illustrations 6.4a, 6.4b, 6.4~ and 6.4d holds it in place.
Overhauling a manual transmission is a difficult job for the do-it-your- Before taking the transmission apart for repair, it will help if you have
selfer. It involves the disassembly and reassembly of many small parts. some idea what area of the transmission is malfunctioning. Certain prob-
Numerous clearances must be precisely measured and, if necessary, lems can be closely tied to specific areas in the transmission, which can
changedwithselectfit spacers and snap-rings. As a result, if transmission make component examination and replacement easier. Refer to the Trou-
~~~ problems arise,-it can be removed and installed by a competentdo-it-your- bleshooting section at the front of this manual for information regarding
selfer, but overhaul should be left to a transmission repair shop. Rebuilt possible sources of trouble.