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Engine
Special Tool(s) Lifting Brackets 303-050 (T70P-6000) or equivalent
Removal All vehicles CAUTION: If the supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold. NOTE: Inspect the engine support insulators for wear or damage. 1. 2. Disconnect the battery cables. For additional information, refer to Section 414-01. Remove the nut and disconnect the ground wire.
3.
Disconnect the electrical connector and detach the wiring harness retainers.
4.
Lift the cover, remove the nut and disconnect the battery cable connector.
5. 6. 7.
Drain the cooling system. For additional information, refer to Section 303-03. Recover the A/C system. For additional information, refer to Section 412-00. Disconnect the windshield washer hose.
8.
NOTE: Mark the hinge locations for installation reference. Remove the four bolts and the hood.
Remove the cooling fan. For additional information, refer to Section 303-03. Remove the power steering pump pulley. For additional information, refer to Section 211-02. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12. Disconnect the mass air flow (MAF) sensor electrical connector.
13.
14.
15.
Release the fuel charging wiring harness from the clips on the bulkhead.
16.
Disconnect the transmission control wiring harness pin-type retainers from the fuel charging wiring harness.
17. 18.
Disconnect the spring lock coupling fuel tube. For additional information, refer to Section 310-00. Disconnect the evaporative emissions (EVAP) return tube and position it aside.
19.
20.
21.
22.
23.
Remove the bolts and position the heater hose bracket aside.
24.
Disconnect the lower radiator hose at the water pump. 1. 2. Release the clamp. Disconnect the radiator hose.
25.
26.
NOTE: Cover the accumulator opening to prevent contamination. Disconnect the A/C tube from the accumulator. Discard the O-ring seal.
27.
Remove the nut and disconnect the A/C tube from the condenser.
28.
Disconnect the accelerator and the speed control cables from the throttle body.
29.
30.
Remove the accelerator and the speed control cables from the bracket and position aside.
31.
32.
33.
Remove the nut and disconnect the A/C tube from the condenser. Discard the O-ring seal.
34.
35.
Disconnect the electrical connector and remove the differential pressure feedback exhaust gas recirculation (EGR) system from the EGR tube.
36.
Remove the EGR valve tube. 1. 2. Disconnect the EGR tube fittings. Remove the EGR tube.
37. 38.
Remove the starter. For additional information, refer to Section 303-06. Remove the pushpins.
39.
Remove the nut and detach the battery cable retainer bracket.
4x4 vehicles 40. Install a suitable jack stand under the transfer case.
4x2 vehicles
41.
WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury. Support the transmission with a transmission jack.
All vehicles 42. Remove the two bolts and position the RH heat shield aside.
43.
NOTE: LH shown, RH similar. Disconnect the two heated oxygen sensor electrical connectors.
44.
NOTE: RH shown, LH similar. Disconnect the two catalyst monitor sensor electrical connectors.
45.
46.
Remove the RH heat shield bolt and remove the heat shield.
47.
48.
Remove the two nuts and the plastic shield on the right side of the crossmember.
49.
50.
4x2 vehicles 51. Remove the bolts and cable bracket from the transmission.
All vehicles 52. Remove the transmission support insulator nuts and remove the crossmember.
53.
Remove the bolts, springs, flag nuts and separate the muffler from the converter. Discard the gasket. Discard the flag nuts.
54.
55.
NOTE: The assistance of another technician may be required. Remove the transmission-mounted exhaust hanger, the three-way converter system and the RH heat shield. 1. 2. Remove the bolt and the converter assembly. If required, remove the second bolt and mount.
56.
57.
4x4 vehicles 58. Index-mark the front axle pinion flange and the front driveshaft.
59.
Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
60.
61.
62.
CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause the boot to tear. CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off the spider. Remove the front driveshaft.
All vehicles
63.
NOTE: The axle pinion flange is shown, the transfer case output flange, if equipped, is similar. Mark the driveshaft flange to the rear axle pinion flange, and if equipped, the transfer case rear output flange for assembly reference.
64.
4x2 vehicles 65. Index-mark the driveshaft at the six o'clock position.
4x4 vehicles 66. Remove the four transfer case flange bolts.
All vehicles
67.
CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. NOTE: Do not rotate the driveshaft. Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft.
4x2 vehicles 68. Index-mark the transmission output shaft at the six o'clock position. 1. 2. Pull the seal away from the transmission output shaft. Mark the output shaft at the six o'clock position.
All vehicles 69. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.
70.
Disconnect the RH heated oxygen sensor electrical connector from the transmission.
71.
72.
Disconnect the LH heated oxygen sensor electrical connector retainer and the harness clip from the transmission.
73.
74.
NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation. Remove the four torque converter nuts. Rotate the crankshaft to access all the nuts.
75.
76.
77.
78.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector. Remove the screw and disconnect the solenoid body electrical connector.
79.
80.
CAUTION: Do not damage the cooler tubes. Hold the transmission case fitting with a wrench. Disconnect the transmission cooler tubes.
81.
Disconnect the cooler tubes and allow them to drain into a suitable container.
82.
Remove the nut and the cooler tubes and the cooler tube bracket.
4x4 vehicles
83.
WARNING: Secure the transmission to the jack with a safety chain. Failure to follow these instructions can result in personal injury. Support the transmission with a transmission jack.
84.
86. 87.
88.
Disconnect the power steering return hose and allow it to drain into a suitable container.
89.
Drain the engine oil. Install the drain plug when finished.
90.
91. 92.
Lower the vehicle. Remove the bolt and power steering tube support bracket.
93.
Disconnect the power steering pressure tube from the power steering pump.
94.
95.
96.
97.
98.
99.
100.
Attach a floor crane to the Spreader Bar and remove the engine.