REMOVAL & INSTALLATION
Fig. 1: Use guide pins when removing and installing the
Fig. 2: Exploded view of the transmission mounting — 85mm
5-speed shown, others similar
1. Place the transmission in third or fourth gear.
2. Jack up your vehicle and support it with jackstands.
3. Drain the transmission.
4. Unplug the speedometer cable or Vehicle Speed Sensor (VSS) connector, back-
up lamp wire and any other wires that would interfere with transmission removal. 5. Remove the gearshift lever. Plug the opening to keep out dirt. 6. Remove driveshaft after making the position of the shaft to the flange. 7. On 4WD models, remove the transfer case.
8. If necessary, remove the parking brake and controls.
9. Remove the exhaust pipes.
10. If equipped, remove the clutch slave cylinder and position it aside. 11. Position a transmission jack or its equivalent under the transmission to support it. 12. Remove the crossmember. Visually inspect to see if other equipment, brackets or
lines must be removed to permit removal of transmission.
NOTE: Mark position of crossmember when removing to prevent incorrect
installation. The tapered surface should face the rear.
13. Remove the flywheel housing underpan.
14. On NVG 4500 models, unbolt the transmission-to-bell housing bolts. 15. On all except the NVG 4500 models, remove the top two transmission-to-housing
bolts and insert two guide pins.
NOTE: The use of guide pins will not only support the transmission but will
prevent damage to the clutch disc. Guide pins can be made by taking two
bolts, the same as those just removed only longer, and cutting off the
heads. Cut a slot in the head that will receive a screwdriver. Be sure to
support the clutch release bearing and support assembly during removal of
the transmission. This will prevent the release bearing from falling out of
the flywheel housing.
16. On all except the NVG 4500 models, remove the remaining bolts and slide
transmission straight back from engine. Use care to keep the transmission drive
gear straight in line with clutch disc hub.
17. Remove the transmission from beneath your vehicle.
Installation is the reverse of removal but please note the following important
18. Make sure the transmission is in third or fourth gear. On NVG transmissions,
place the transmission in Neutral.
19. Coat the input shaft splines with high temperature grease.
20. On all except the NVG 4500 models, install the guide pins in the top 2 bolt holes. 21. On NVG 4500 models, install the transmission-to-housing bolts.
Do not force the transmission into the clutch disc hub. Do not let the transmission
hang unsupported in the splined portion of the clutch disc.
22. On all except the NVG 4500 models, tighten the transmission-to-engine bolts to
35 ft. lbs. (47 Nm). On NVG 4500 models tighten transmission-to-housing bolts to
74 ft. lbs. (100 Nm).
Driven Disc and Pressure Plate
REMOVAL & INSTALLATION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.
Fig. 1: Exploded view of typical clutch assembly components