Here's a general outline of the process. Remember this is a simplified version and crucial steps are omitted for brevity. Always refer to a factory service manual for detailed instructions and torque specifications.
1. Preparation:
* Safety First: Disconnect the negative battery terminal. Use jack stands to safely support the vehicle. Wear safety glasses and gloves.
* Gather Tools: You'll need a variety of tools, including sockets, wrenches, a transmission jack, a torque wrench, possibly a clutch alignment tool, and potentially a puller for the driveshaft. A helper is highly recommended.
* Fluid Drainage: Drain the transmission fluid and transfer case fluid.
2. Disconnect Components:
* Driveshaft: Disconnect the driveshaft from the transmission and the differential. This often requires disconnecting the center carrier bearing and possibly using a driveshaft puller.
* Shift Linkage: Disconnect the shift linkage from the transmission.
* Clutch Cable: Disconnect the clutch cable.
* Speed Sensor: Disconnect the vehicle speed sensor (VSS) if applicable.
* Wiring Harness: Disconnect any electrical connectors from the transmission.
* Exhaust System: You may need to loosen or remove parts of the exhaust system to gain access.
* Starter: Remove the starter motor for better access.
3. Remove Transmission:
* Crossmember: Remove the transmission crossmember. This may involve removing bolts connecting it to the frame.
* Bell Housing Bolts: Carefully remove the bell housing bolts connecting the transmission to the engine.
* Transmission Jack: Use a transmission jack to carefully support the transmission as you separate it from the engine.
* Pilot Bearing: Pay close attention to the pilot bearing (the bearing in the crankshaft that the transmission input shaft rides on). It may need to be removed and replaced.
* Clutch: The clutch is likely to come out with the transmission, so be prepared to handle it.
4. Transmission Removal:
* Slowly and Carefully: Once all bolts and connections are removed, slowly lower the transmission using the jack. Maneuver it out from under the vehicle.
5. Reassembly (Reverse Order):
Reassembly is the reverse of the disassembly process. Pay close attention to torque specifications for all bolts and nuts. Improper torque can lead to catastrophic failure. Remember to replace any worn or damaged parts, such as the clutch, pilot bearing, seals, and gaskets.
Important Considerations:
* Clutch: Replacing the clutch is highly recommended whenever removing a manual transmission.
* Pilot Bearing: The pilot bearing should always be inspected and replaced if necessary.
* Alignment: Proper alignment of the clutch disc during reassembly is crucial. A clutch alignment tool is highly recommended.
* Torque Specifications: Always refer to a factory service manual for the correct torque specifications for all fasteners.
* Professional Assistance: This is a complex job. If you're not comfortable performing this task, seek professional assistance from a qualified mechanic.
This procedure is a simplified overview. Always consult a factory service manual for your specific vehicle for detailed instructions, torque specifications, and safety precautions. Improper procedures can lead to serious damage to your vehicle or personal injury.
