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Service Information: Removal

Fig 1: View Of Transfer Case Skid Plate
GC0009452Courtesy of DAIMLERCHRYSLER CORP.
  1. Disconnect the negative battery cable.
  2. Raise and support the vehicle
  3. Remove any necessary skid plates. (Refer to FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - REMOVAL)
  4. Mark propeller shaft and axle companion flanges for assembly alignment.
  5. Remove the rear propeller shaft. (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - REAR/PROPELLER SHAFT - REMOVAL)
  6. Remove the front propeller shaft, if necessary. (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - FRONT/PROPELLER SHAFT - REMOVAL)
    Fig 2: Transmission-To-Engine Mounting
    GC0005195Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - ENGINE TO TRANSMISSION COLLAR
    3 - TRANSMISSION
  7. Remove the engine to transmission collar (2).
  8. Remove the exhaust support bracket from the rear of the transmission.
  9. Disconnect and lower or remove any necessary exhaust components.
  10. Remove the starter motor.
  11. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
    Fig 3: Locating Output Speed Sensor
    G04285202Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - OUTPUT SPEED SENSOR
  12. Disengage the output speed sensor (2) connector from the output speed sensor.
    Fig 4: Locating Input Speed Sensor
    G04285146Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - INPUT SPEED SENSOR
  13. Disengage the input speed sensor (2) connector from the input speed sensor.
    Fig 5: Locating Transmission Solenoid/TRS Assembly
    G04285147Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
  14. Disengage the transmission solenoid/TRS assembly (2) connector from the transmission solenoid/TRS assembly.
    Fig 6: Locating Line Pressure Sensor
    G04285148Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSMISSION
    2 - LINE PRESSURE SENSOR
  15. Disengage the line pressure sensor (2) connector from the line pressure sensor.
    Fig 7: Locating Shift Cable At Transmission
    GC0009630Courtesy of DAIMLERCHRYSLER CORP.
    1 - GEARSHIFT CABLE
    2 - GEARSHIFT CABLE BRACKET
    3 - MANUAL SHIFT LEVER
  16. Disconnect gearshift cable (1) from transmission manual valve lever (3).
  17. Remove the gearshift cable (1) from the shift cable support bracket (2).
    Fig 8: Remove Transmission Cooler Lines
    GC0009629Courtesy of DAIMLERCHRYSLER CORP.
    1 - COOLER LINE FITTINGS
    2 - CLIPS
  18. Disconnect transmission fluid cooler lines at transmission fittings (1) and clips (2).
    Fig 9: Rear Transmission Crossmember
    GC0009449Courtesy of DAIMLERCHRYSLER CORP.
    1 - CROSSMEMBER
    2 - REAR TRANSMISSION MOUNT
  19. Support rear of engine with safety stand or jack.
  20. Raise transmission slightly with service jack to relieve load on crossmember (1) and supports (2).
  21. Remove bolts securing rear support and cushion to transmission and crossmember.
  22. Remove bolts attaching crossmember to frame and remove crossmember.
    Fig 10: Removing/Installing Transmission
    G04285152Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - TRANSMISSION
  23. Remove transfer case.
  24. Remove all remaining converter housing bolts.
  25. Carefully work transmission and torque converter assembly (2) rearward off engine (1) block dowels.
  26. Hold torque converter in place during transmission removal.
  27. Lower transmission and remove assembly from under the vehicle.
  28. To remove torque converter, carefully slide torque converter out of the transmission.
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