Transmission Replacement NV3500

Tools Required

J 36221 Quick Connect Disengagement Tool

1. Shift the transmission into 3RD or 4TH speed gear.
2. Remove the shift lever and boot. Refer to Shift Lever Replacement .
3. Raise the vehicle.
4. Drain the transmission oil. Refer to Fluid Replacement .
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
6. Remove the transfer case if the vehicle is equipped with four wheel drive. Refer to Transfer Case Replacement in Transfer Case.



7. Disconnect the wiring harness connector from the vehicle speed sensor.



8. Disconnect the wiring harness connector from the backup lamp switch.
9. Disconnect the wiring harness retainers from the transmission.



10. Use the J 36221 . Depress the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.



11. Remove the clutch housing cover.
12. Remove the transmission rear mount.
13. Support the transmission. Use a suitable safety stand.
14. Remove the frame crossmember. Refer to Rear Bumper Brace Replacement in Frame and Bumpers.



15. Remove the transmission to the clutch housing bolts and studs.
16. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.
17. Remove the transmission from the vehicle.

Important: 

•	Do not force the transmission into the clutch.

•	Do not let the transmission hang from the clutch.

•	Leave the safety stand under the transmission for support.

1. Install the transmission:

1.1.	Put a thin coat of high-temperature grease on the main drive gear splines.

1.2.	Shift the transmission into 3RD or 4TH speed gear.

1.3.	Rotate the transmission clockwise onto the clutch hub splines.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1.4.	Install the bolts and the studs securing the transmission to the engine.

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

2. Install the frame crossmember. Refer to Rear Bumper Brace Replacement in Frame and Bumpers.
3. Install the transmission rear mount.
4. Remove the safety stand from beneath the transmission.



5. Install the hydraulic clutch line to the concentric slave cylinder quick connect.
6. Install the wiring harness retainers to the transmission.



7. Install the electrical connector to the backup lamp switch.



8. Install the electrical connector to the vehicle speed sensor.
9. Install the transfer case if removed. Refer to Transfer Case Replacement in Transfer Case.
10. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
11. Install the parking brake and controls, if removed. Refer to Parking Brake Replacement in Parking Brake.
12. Fill the transmission with new oil. Refer to Fluid Replacement .
13. Remove the safety stands.
14. Lower the vehicle.
15. Install the shift lever and the boot. Refer to Shift Lever Replacement .

Transmission Replacement NV4500 RWD

Tools Required

J 36221 Clutch Line Disconnect Tool

1. Shift the transmission into 3RD or 4TH speed gear.
2. Remove the transmission shift lever and the boot. Refer to Shift Lever Replacement .
3. Raise the vehicle.
4. Drain the transmission oil. Refer to Fluid Replacement .
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
6. Remove the parking brake and controls, if used. Refer to Parking Brake Replacement in Parking Brake.
7. Disconnect the wiring harness connector from the backup lamp switch and from the vehicle speed sensor.
8. Disconnect the wiring harness retainers from the transmission.



9. Disconnect the hydraulic clutch line from the concentric slave cylinder using the J 36221 .



10. Remove the transmission vent hose from the transmission.
11. Remove the transmission rear mount.
12. Support the transmission.
13. Remove the frame crossmember. Refer to Rear Bumper Brace Replacement in Frame and Bumpers.
14. Remove the transmission to engine bolts.
15. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and clutch cover.



16. Remove the transmission from the vehicle.

Important: 

•	Do not force the transmission into the clutch.

•	Do not let the transmission hang from the clutch.

•	Leave the safety stand under the transmission for support.

1. Install the transmission.

1.1.	Put a thin coat of high-temperature grease on the main drive gear splines.

1.2.	Shift the transmission into 3RD or 4TH speed gear.

1.3.	Rotate the transmission clockwise onto the clutch hub splines.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1.4.	Install the transmission to the engine bolts and washers.

Tighten
Tighten the bolts to 100 N·m (74 lb ft).

2. Install the transmission to engine bolts.

Tighten
Tighten the studs to 31 N·m (23 lb ft).

3. Install the frame crossmember. Refer to Rear Bumper Brace Replacement in Frame and Bumpers.
4. Install the transmission rear mount.
5. Remove the safety stand from beneath the transmission.



6. Install the transmission vent hose.



7. Install the hydraulic clutch line to the concentric slave cylinder quick connect.
8. Install the wiring harness retainers to the transmission.
9. Connect the following electrical wiring harness connectors:

•	The vehicle speed sensor

•	The backup lamp switch

10. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
11. Install the parking brake and controls, if removed. Refer to Parking Brake Replacement in Parking Brake.
12. Fill the transmission with new oil. Refer to Fluid Replacement .
13. Remove the safety stands.
14. Lower the vehicle.
15. Install the shift lever and the boot. Refer to Shift Lever Replacement .

Transmission Replacement NV4500 4WD

Tools Required

J 36221 Quick Connect Disengagement Tool

1. Shift the transmission into 3RD or 4TH speed gear.
2. Remove the shift lever. Refer to Shift Lever Replacement .
3. Drain the transmission oil. Refer to Fluid Replacement .
4. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
5. Remove the transfer case. Refer to Transfer Case Replacement in Transfer Case.
6. Remove the parking brake and controls, if used. Refer to Parking Replacement in Parking Brake.
7. Disconnect the following electrical wiring harness connectors:

•	The vehicle speed sensor

•	The backup lamp switch

8. Disconnect the wiring harness retainers from the transmission.



9. Disconnect the hydraulic clutch line from the concentric slave cylinder using the J 36221 .



10. Remove the transmission vent hose.
11. Remove the transmission rear mount.
12. Support the transmission. Use a suitable safety stand.
13. Remove the frame crossmember. Refer to Rear Bumper Brace Replacement in Frame and Bumpers.



14. Remove the transmission to engine bolts.
15. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and clutch cover.
16. Remove the transmission from the vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the clutch housing to the engine, if removed.

Tighten
Tighten the studs to 100 N·m (74 lb ft).

Important: 

•	Do not force the transmission into the clutch.

•	Do not let the transmission hang from the clutch.

•	Leave the safety stand under the transmission for support.

2. Install the transmission.

2.1.	Put a thin coat of high-temperature grease on the main drive gear splines.

2.2.	Shift the transmission into 3RD or 4TH speed gear.

2.3.	Rotate the transmission clockwise onto the clutch hub splines.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2.4.	Install the transmission to the clutch housing bolts and washers.

Tighten
Tighten the bolts to 31 N·m (23 lb ft).

3. Install the frame crossmember. Refer to Rear Bumper Brace Replacement in Frame and Bumpers.
4. Install the transmission rear mount.
5. Remove the safety stand from beneath the transmission.



6. Install the transmission vent hose.



7. Install the hydraulic clutch line to the concentric slave cylinder quick connect.
8. Install the wiring harness retainers to the transmission.
9. Connect the following electrical wiring harness connectors:

•	The vehicle speed sensor

•	The backup lamp switch

10. Install the transfer case. Refer to Transfer Case Replacement in Transfer Case.
11. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
12. Install the parking brake and controls, if removed. Refer to Parking Brake Replacement in Parking Brake.
13. Fill the transmission with new oil. Refer to Fluid Replacement .
14. Remove the safety stands.
15. Lower the vehicle.
16. Install the shift lever to the transmission. Refer to Shift Lever Replacement .