Transmission Replacement

Transmission Replacement

^ Tools Required
- J 42371 Clutch Line Removal Tool

Removal Procedure





1. Shift the transmission into 3rd or 4th speed gear.
2. Remove the shift lever.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Drain the transmission oil.
5. Remove the rear propeller shaft.
6. Remove the exhaust manifold pipe.
7. Remove the 2 bolts and nut securing the support to the transmission and engine.





8. Remove the 2 bolts securing the support to the transmission and engine.





9. Use the J 42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.
10. Disconnect the wiring harness and connector from the vehicle speed sensor, backup lamp switch, and transmission harness retainers.





11. Remove the bolts securing the clutch housing cover to the transmission.
12. Remove the transmission rear mount.
13. Support the transmission with a transmission jack.
14. Remove the bolts securing the transmission to the engine.
15. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.
16. Remove the transmission from the vehicle.
17. Remove the clutch plate and the clutch cover from the engine flywheel if required.





18. If required, remove the insulator from the vehicle.

Installation Procedure





1. Install the clutch plate and the clutch cover to the engine flywheel if removed.
2. If removed, install the insulator to the vehicle.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the transmission:
3.1. Ensure the transmission is positioned in the 3rd or 4th speed gear.
3.2. Rotate the transmission clockwise onto the clutch hub splines.
3.3. Install the bolts securing the transmission to the engine.
Tighten the bolts to 47 Nm (35 ft. lbs.).





4. Install the clutch housing cover using the bolts.
Tighten the bolts to 14 Nm (10 ft. lbs.).
5. Install the transmission rear mount.





6. Install the clutch line to the concentric slave cylinder.





7. Install the two bolt securing the right side support to the transmission and engine.
Tighten the bolts to 50 Nm (37 ft. lbs.).





8. Install the two bolts and nut securing the left side support brace to the transmission and engine.
Tighten the bolts and nuts to 50 Nm (37 ft. lbs.).
9. Install the exhaust manifold pipe.
10. Install the rear propeller shaft.
11. Install the shift tower.
12. Fill the transmission with transmission fluid.
13. Install the shift lever.