exj_21a.pdf

TRANSMISSION AND TRANSFER CASE

21 - 1

TRANSMISSION AND TRANSFER CASE

TABLE OF CONTENTS

page

NV3550 MANUAL TRANSMISSION ............ 1

NV231 TRANSFER CASE .................... 5

NV3550 MANUAL TRANSMISSION

TABLE OF CONTENTS

page

REMOVAL AND INSTALLATION

TRANSMISSION - 2.5L TURBO DIESEL

ENGINE ...............................1

SPECIFICATIONS

TORQUE ................................4

REMOVAL AND INSTALLATION

5. Remove exhaust pipe and heat shield.

6. Mark the front and rear propeller shafts for

installation alignment (Fig. 2).

TRANSMISSION - 2.5L TURBO DIESEL ENGINE

REMOVAL

1. Disconnect

and

isolate

the

negative

battery

cable.

2. Remove the floor console, shifter boot and

shifter. Refer to group 23, Body for the procedure.

3. Raise the vehicle on a hoist.

4. Drain the transmission fluid (Fig. 1).

Fig. 2 Marking Propeller Shaft and Axle Yoke

1 – MARK BOTH YOKES FOR ALIGNMENT AT INSTALLATION

7. Remove the front propeller shaft.

8. Remove the rear propeller shaft.

9. Remove the transmission skid plate.

10. Disconnect the transfer case linkage and vehi-

cle speed sensor electrical connector and vent tube

hose (Fig. 3).

11. Support

Fig. 1 Drain Plug and Backup Light Switch Location

1 – GEAR CASE

2 – BACKUP LIGHT SWITCH

3 – DRAIN PLUG

the

engine

with

adjustable

jack

stand.

12. Place a transmission jack under the transmis-

sion and secure the transmission with safety chains.

21 - 2

TRANSMISSION AND TRANSFER CASE

REMOVAL AND INSTALLATION (Continued)

Fig. 4 Engine Speed Sensor

1 – ENGINE SPEED SENSOR

2 – GROMMET

3 – MOUNTING BOLT(S)

4 – LEFT REAR OF ENGINE

5 – TRANSMISSION

Fig. 3 Vehicle Speed Sensor

1 – SENSOR ELECTRICAL CONNECTOR

2 – 4WD TRANSFER CASE EXTENSION

3 – VEHICLE SPEED SENSOR

6. Install

the

two

(2)

upper

clutch

housing

engine bolts. Tighten the bolts to 36.6 N·m.

7. Install the two (2) mid clutch housing to engine

bolts. Tighten the bolts to 58.3 N·m.

8. Raise

13. Remove the rear transmission mount.

14. Remove the rear crossmember.

15. Remove the transfer case assembly. Refer to

Transfer Case removal later in this Group.

16. Lower the engine and transmission no more

than 7.6 cm.

17. Remove the two (2) upper and two (2) mid

clutch housing to engine bolts.

18. Remove the engine speed sensor (crankshaft

position sensor) (Fig. 4).

19. Remove

the

engine

and

transmission

with

the

adjustable jackstand.

9. Install

the

transfer

case

assembly.

Refer

Transfer Case installation later in this Group.

10. Install the rear crossmember.

11. Install the rear transmission mount.

12. Connect the transfer case linkage and vehicle

speed sensor electrical connector and vent tube (Fig.

3).

13. Install the transmission skid plate.

14. Install the front and rear propeller shafts in

there original position, using the reference marks

scribed earlier.

15. Install the exhaust pipe and heat shield.

16. Remove the transmission jack.

17. Fill

the

clutch

slave

cylinder

from

the

clutch housing.

20. Remove the lower transmission bolts.

21. Remove the transmission assembly from the

vehicle.

INSTALLATION

1. Mount the transmission on a transmission jack

and secure the transmission with safety chains.

2. Position the transmission in the vehicle (Fig. 5).

3. Install

the

transmission

with

the

proper

fluid

(Fig. 7).

18. Remove the adjustable jackstand from under

the engine.

19. Lower the vehicle from the hoist.

20. Install the shifter, shifter boot and floor con-

sole.

21. Reconnect the negative battery cable.

22. Using the DRB III Scan Tool clear any DTC’s

and reset customer preferences.

the

two

(2)

lower

transmission

bolts.

Tighten the bolts to 74.6 N·m.

4. Install the clutch slave cylinder on the clutch

housing.

5. Install the engine speed sensor (crankshaft posi-

tion sensor) on the vehicle (Fig. 4).

TRANSMISSION AND TRANSFER CASE

21 - 3

SPECIFICATIONS (Continued)

Fig. 5 Transmission to Engine Mounting

1 – ENGINE BLOCK

2 – FLYWHEEL

3 – CLUTCH HOUSING AND TRANSMISSION

4 – CLUTCH COVER

5 – CLUTCH DISC

21 - 4

TRANSMISSION AND TRANSFER CASE

SPECIFICATIONS (Continued)

SPECIFICATIONS

TORQUE

DESCRIPTION TORQUE

Clutch Housing to Engine Top (2) Bolts . . 36.6 N·m

(27 ft. lbs.)

Clutch Housing to Engine Mid-Point

(2) Bolts ............... 58.3 N·m (43 ft. lbs.)

Clutch Housing to Engine Bottom

(2) Bolts ............... 74.6 N·m (55 ft. lbs.)

Clutch Housing to Transmission bolts . . . 38.0 N·m

(28 ft. lbs.)

Transfer Case to Transmission

Attaching Nuts ........... 35N·m(26ft.lbs.)

Propeller Shaft Bolts ...... 26.5 N·m (19.5 ft. lbs.)

Fig. 6 Clutch Housing to Transmission

1 – TRANSMISSION

2 – CLUTCH HOUSING

3 – CLUTCH HOUSING BOLT

4 – RELEASE BEARING

5 – RELEASE FORK

6 – PIVOT

Fig. 7 Fill Plug Location

1 – GEAR CASE

2 – FILL PLUG

TRANSMISSION AND TRANSFER CASE

21 - 5

NV231 TRANSFER CASE

TABLE OF CONTENTS

page

REMOVAL AND INSTALLATION

TRANSFER CASE .........................5

SPECIFICATIONS

TORQUE ................................5

REMOVAL AND INSTALLATION

TRANSFER CASE

REMOVAL

(1) Shift transfer case into Neutral.

(2) Raise vehicle.

(3) Drain transfer case lubricant.

(4) Mark front and rear propeller shaft yokes for

alignment reference.

(5) Support transmission with jack stand.

(6) Remove rear crossmember and skid plate, if

equipped.

(7) Disconnect

and

support

front/rear

propeller

shafts at transfer case.

(8) Disconnect vehicle speed sensor wires.

(9) Disconnect

Fig. 1 Transfer Case Mounting

1 – MOUNTING STUDS

2 – TRANSFER CASE

3 – TRANSMISSION

transfer

case

linkage

rod

from

range lever.

(10) Disconnect transfer case vent hose (Fig. 1)

and indicator switch harness, if necessary.

(11) Support transfer case with transmission jack.

(12) Secure transfer case to jack with chains.

(13) Remove nuts attaching transfer case to trans-

mission.

(14) Pull transfer case and jack rearward to disen-

gage transfer case.

(15) Remove transfer case from under vehicle.

(8) Align

and

connect

propeller

shafts.

Tighten

shaft attaching bolts to 26.5 N·m torque.

(9) Fill transfer case with correct fluid. Refer to

Recommended Lubricant And Fill Level section for

proper fluid and capacity.

(10) Install rear crossmember and skid plate, if

equipped. Tighten crossmember bolts.

(11) Remove transmission jack and support stand.

(12) Connect shift rod to transfer case range lever.

(13) Adjust transfer case shift linkage.

(14) Lower vehicle and verify transfer case shift

operation.

INSTALLATION

(1) Mount transfer case on a transmission jack.

(2) Secure transfer case to jack with chains.

(3) Position transfer case under vehicle.

(4) Align

transfer

case

and

transmission

shafts

and install transfer case on transmission.

(5) Install and tighten transfer case attaching nuts

to 35 N·m (Fig. 1).

(6) Connect vehicle speed sensor wires, and vent

hose.

(7) Connect indicator switch harness to transfer

case switch, if necessary. Secure wire harness to clips

on transfer case.

SPECIFICATIONS

TORQUE

DESCRIPTION TORQUE

Plug, Drain/Fill ...................... 40N·m

Nuts, Mounting ...................... 35N·m

Switch, Indicator ..................... 26N·m

NOTE: Do no reuse bearing straps or bolts. Discard

and replace with new.

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