Removal Procedure

NOTICE:
- Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
- When tilting down the rear of the driveline, observe the clearance between the rear of the engine and the composite dash panel. Do not allow the engine to rest unsupported against the composite dash panel, or vehicle damage may result.
- When lowering and removing the rear of the driveline, observe the clearance between the rear of the transaxle assembly and the underbody to prevent damage.

^ Tools Required:
- J 42055 Transmission Support Fixture

CAUTION: Disconnect the negative battery cable under the following circumstances:
- When installing an electrical unit.
- When a tool or equipment could easily come into contact with "live" exposed electrical terminals.
Failure to disconnect the negative battery terminal may result in personal injury or damage to the vehicle's components. Turn OFF the vehicle ignition, unless instructed otherwise.

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the rear tire and wheel assemblies.
4. Shift the transmission into NEUTRAL.
5. Remove the intermediate exhaust pipe.





6. Tie off the LH muffler assembly to the underbody to support out of the way.
7. Remove the RH muffler assembly.
8. Remove the driveline tunnel closeout panel.





9. Using a flat bladed screwdriver, remove the rear bell housing access plug.

Important: The following step must be performed to assure proper torque converter balance during installation.

10. Matchmark the transmission flexplate to the transmission torque converter through the access hole in the rear bell housing.
11. Remove the transmission flexplate to transmission torque converter bolts.





12. Remove the two plug bolts from the front of driveline support assembly.

Important:
- The propeller input shaft front bearing positioning bolts are intended to remain torqued to specification and in place UNTIL INSTRUCTED in the installation procedure.
- Failure to use the minimum length fastener specified will prevent proper retention of the propeller input shaft front bearing during disassembly or installation.

13. Install two bolts, M10-1.5 X 55 mm, or longer, in place of the plug bolts. (The long bolts are located to maintain the propeller input shaft front bearing in original position during removal and installation.)
- Tighten the propeller input shaft front bearing positioning bolts to 35 Nm (26 ft. lbs.).





14. Using a flat bladed screwdriver, remove the engine flywheel housing access plug.





15. Loosen the propeller shaft hub clamp bolt (1). Rotate the engine at the flywheel, if necessary for alignment.





16. Shift the transmission into PARK.
17. Remove the nuts retaining the transmission shift cable bracket to the transmission.





18. Disconnect the transmission shift control cable from the transmission shift lever. Unsnap to release the cable.
19. Reposition the transmission shift cable and bracket.





20. Remove the electronic brake and traction control module (EBTCM) LH mounting bracket bolts.





21. Remove the EBTCM LH mounting bracket with the EBTCM rubber insulators. (The EBTCM insulators will remain attached to the LH mounting bracket).





22. Pull lightly to release the EBTCM from the insulator attached to the EBTCM RH mounting bracket.
23. Tie off the EBTCM to the underbody to support out of the way.
24. Remove the rear transverse spring.
25. Support the lower control arm with a straight jack.
26. Disconnect the outer tie rod end from the suspension knuckle.





27. Remove the shock absorber lower mounting bolt.
28. Disconnect the lower ball joint from the suspension knuckle.
29. Remove the straight jack from the control arm.
30. Repeat steps 25 through 29 for the other side of the vehicle.





31. Assemble the J 42055.
32. Install the J 42055 to a transmission jack.
33. Position and firmly secure the J 42055 with the transmission jack to the transmission.
34. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
35. Remove the differential to transmission lower nut. (Removing the nut at this time will aid in separating the differential from the transmission after the driveline has been removed from the vehicle.)





36. Remove the transaxle mount to rear crossmember nuts.





37. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
38. BY HAND, remove the rear suspension crossmember retaining nuts.





39. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.





40. Remove the transaxle mount bracket to differential bolts.
41. Remove the transaxle mount with bracket. (Removing the transaxle mount will allow for greater stability on a workbench after the driveline is removed.)





42. Using a pry bar, CAREFULLY release the axle shafts from the differential.
43. Tie off the axle shafts to the underbody to support out of the way. (The LH muffler assembly pipe toward the rear offers a good location to help support the LH axle shaft.)
44. Using pliers, compress and release the four retainers securing the wiring harness along the driveline support assembly, then push the harness up out of the way.
45. SLOWLY lower the driveline approximately 2 inches, while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.





46. Disconnect the vehicle speed sensor (VSS) electrical connector.
47. Disconnect the wiring harness retainer from the stud at the differential rear cover.





48. Disconnect the wiring harness retainer clip from the top of the differential.





49. Disconnect the transmission harness 20-way connector. Depress both tabs on the connector and pull straight up; do not pry the connector.
50. Disconnect the park/neutral position switch electrical connectors.





51. Remove the bolt retaining the transmission wiring harness to the LH side of the transmission case.





52. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt, and observe the relationship between the top rear of the differential and the lowest part of the rear compartment panel floor (the center storage compartment between the frame rails); the differential should not be lowered more than approximately EVEN with the specified body point of reference. (The engine positive crankcase ventilation (PCV) pipes which route along the rear of the engine intake manifold will likely contact the dash panel.)
53. Release the wiring harness from the harness retainer along the top of the transmission.
54. Check to be sure that the wiring harness is free from the driveline being removed.





55. Disconnect the transmission oil cooler rear pipes from the junction fittings at the engine flywheel housing.





56. Using a block of wood to protect the engine oil pan, place a straight jack under the rear of the engine oil pan to support the engine from stressing the composite dash panel.
57. Remove the five driveline support assembly to engine flywheel housing bolts.
58. Carefully bend the wiring harness bracket away from the driveline, toward the driveline tunnel wall in order to make a clear removal path for the driveline.

Important: The aid of an assistant will be necessary for the remaining steps.





59. Have an assistant insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the engine flywheel housing, then begin to pry the driveline loose from the engine.





60. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
61. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt and pulling the driveline away from the engine UNTIL the propeller input shaft at the front of the driveline support assembly just clears the engine flywheel housing.
62. SLOWLY lower the driveline completely out of the vehicle.
63. Position the chainfall, or equivalent, of a lift device in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly.
64. Using the lift device, raise the driveline to relieve the weight from the transmission jack.





65. Disconnect the J 42055 from the transmission jack ONLY, the J 42055 will provide stability to the driveline components while working on a bench.
66. Position the driveline on a workbench with the lift device still attached.
67. Support the driveline support assembly and the differential for additional balance.
68. Remove the lift device from the driveline.





69. Disconnect the transmission oil cooler rear pipes from the fittings on the transmission.





70. Remove the transmission to driveline assembly bolts/studs.
71. Insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the transmission, then begin to pry the driveline support assembly loose from the transmission.
72. Slowly slide the driveline support assembly away from the transmission while supporting the transmission torque converter.
73. Using a strap positioned from side to side, secure the transmission torque converter to the transmission.





74. Remove the differential to transmission bolts and nuts.

Important: Use care when separating the differential from the transmission to not damage the transmission output shaft seal in the differential plate.

75. SLOWLY slide the differential from the transmission.





76. Remove the differential plate from the differential.
77. Remove the transmission from the J 42055, if necessary.