Chrysler DODGE D150 1993 Service Manual page 1005

21 - 4 NV4500 MANUAL TRANSMISSION
(12) If transmission is to be disassembled for re­
pair, remove drain plug and drain lubricant from
transmission.
(13) move bolts/nuts attaching transmission to rear
mount.
(14) Support transmission with a transmission
jack. Secure transmission to jack with safety chains.
(15) Remove rear crossmember,
(16) Remove bolts attaching clutch slave cylinder
to clutch housing. Then move cylinder aside for
working clearance.
(17) Remove transmission harness wires from clips
on transmission shift cover.
(18) Remove bolts attaching transmission to clutch
housing.
(19) Slide transmission and jack rearward until
drive gear clears clutch housing.
(20) Lower transmission jack and remove trans­
mission from under vehicle.
(21) If transmission will be overhauled, clean
transmission exterior with solvent or with steam
gun.
TRANSMISSION INSTALLATION—2-WHEEL DRIVE
(1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com­
ponents:
• drive gear splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bearing
• release bearing bore
• release fork
• release fork ball stud
• propeller shaft slip yoke
(2) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(3) Mount transmission on jack and position trans­
mission under vehicle.
(4) Raise transmission until drive gear is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start drive gear
in release bearing, clutch disc and pilot bushing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after drive gear has entered clutch disc.
(7) Install and tighten transmission-to-clutch hous­
ing bolts to 108 N*m (80 ft. lbs.) torque.
(8) Install clutch slave cylinder.
(9) Connect speed sensor and backup light switch
wires.
(10) Position transmission harness wires in clips
on shift cover.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Align and connect propeller shaft.
(15) Fill transmission with required lubricant, if
necessary.
(16) Lower vehicle.
(17) Install shift lever on transmission stub lever.
(18) Install shift boot and bezel.
(19) Connect battery negative cable.
TRANSMISSION REMOVAL—4-WHEEL DRIVE
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove shift lever boot and bezel.
(4) Loosen nut attaching shift lever to transmis­
sion stub lever and remove shift lever from stub le­
ver.
(5) Raise- vehicle.
(6) Remove skid plate if equipped.
(7) If transmission will be disassembled for repair,
remove drain plug and drain lubricant from trans­
mission.
(8) Mark propeller shafts and yokes for assembly
reference.
(9) Disconnect propeller shafts and remove propel­
ler shafts.
(10) Disconnect and remove exhaust system
Y-pipe. Then disconnect and lower remaining ex­
haust pipes for clearance as necessary.
(11) Support engine with adjustable safety stand.
(12) Disconnect speed sensor wires and disconnect
speedometer cable, if equipped.
(13) Disconnect backup light switch wires.
(14) Disconnect transfer case shift linkage at
transfer case range lever.
(15) Remove bolts/nuts attaching transmission to
rear support.
(16) Remove crossmember bolts/nuts and remove
crossmember.
(17) Support transfer case with transmission jack.
Secure transfer case to jack with safety chains.
(18) Remove transfer case attaching nuts.
(19) Move transfer case rearward until input gear
clears transmission mainshaft.
(20) Lower transfer case assembly and move it
from under vehicle.
(21) If transmission is being removed for repair,
remove drain plug and drain lubricant from trans­
mission.
(22) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(23) Remove transmission harness from retaining
clips on transmission shift cover.
(24) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(25) Remove rear crossmember.
(26) Remove clutch slave cylinder splash shield, if
equipped.
(27) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever.
This reduces pressure on lever and release bearing