REMOVAL:
1. Disconnect the negative battery cable(s).
2. Remove the torque converter access cover and inspection plate.
3. Remove the transmission pan, drain the fluid and re-install the pan.
4. Remove the fill tube bracket bolt and pull the tube out of the transmission. Retain the fill tube seal. On 4WD models, it will also be necessary to remove the bolt attached to the transfer case vent tube to the converter housing.
5. Rotate the crankshaft with a pry bar from under the vehicle until the converter bolts are accessible.
6. Mark the drive shaft and pinion yokes for assembly alignment. Disconnect and remove the drive shaft. On 4WD models, remove both drive shafts.
7. Disconnect the electrical wiring from the park/neutral position switch, transmission solenoid, and speed sensor.
8. Disconnect the gearshift rod and shifter shaft assembly from the transmission.
9. Disconnect the TV (throttle valve) cable from the transmission bracket.
10. On 4WD models, disconnect the shifter rod from the transfer case shift lever.
11. Raise the transmission slightly by using a service jack to relieve the load on the cross-member and supports.
12. Remove the bolts securing the rear support and cushion to the transmission and cross-member.
13. Disconnect the vacuum lines and remove the steel line from the cross-member and frame.
14. Remove the bolts attaching the cross-member to the frame. Spread the frame with a Port-A-Power to remove the cross-member.
15. On 4WD models, remove the transfer case with a transmission jack or with the aid of a helper.
16. Disconnect the fluid cooler lines at the transmission.
17. Remove all bell housing bolts.
18. Carefully work the transmission and torque converter assembly rearward off the engine block dowels.
19. Lower the transmission and remove assembly from under the vehicle.
20. Carefully slide the torque converter out of the transmission.
INSTALLATION:
1. Flush the cooler and all cooler lines before installing the transmission.
2. ***NOTE: If new bolts are supplied with the converter, be sure to remove the bolts before installing the transmission.
3. Lubricate the converter drive hub and oil pump seal lip with petroleum jelly.
4. Lubricate the converter pilot hub with transmission fluid.
5. Align and install the torque converter into the oil pump.
6. Carefully insert the converter into the oil pump. Rotate the converter back and forth until it’s fully seated in the pump gears. Two loud “clunks” should be heard to ensure it is seated properly.
7. Position the transmission on a service jack and secure it with chains.
8. Check the condition of the converter drive plate. If the plate is cracked, distorted or damaged, it must be replaced before installation can continue. Also be sure the transmission dowel pins are seated in the engine block and protrude far enough to hold the transmission in alignment.
9. Raise the transmission and align the torque converter with the drive plate, and the bell housing with the engine block.
10. Move the transmission forward. Raise, lower or tilt the transmission to align the bell housing with the engine block dowels.
Related Tags: bd diesel, bell housing, cross member, drive shaft, drive shafts, electrical wiring, negative battery cable, neutral position, position switch, shaft assembly, shift lever, speed sensor, steel line, throttle valve, torque converter, transfer case, transmission pan, vacuum lines, vent tube, yokes
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