Pages 16-20-4, 16-20-4A & 16-20-4B
198916-20-4 Transmission, Manual-M5R2 16-20-4
DESCRIPTION (Continued)
IDENTIFICATION
The Vehicle Safety Compliance Certification Label (located on the driver's door lock pillar) lists applicable transmission identification codes. For identification of the label codes, refer to Section 10-01. Manual transmissions are equipped with service identification tags. The M5R2 transmission service tag is located on the LH side of the transmission.
DIAGNOSIS AND TESTING
For diagnosis and testing procedures, refer to Section 16-10.
REMOVAL AND INSTALLATION
Transmission Removal
1. Disconnect battery ground cable.
2. Shift transmission into the NEUTRAL position.
3. Remove shift knob.
4. Remove console top cover.
5. Remove two shifter retaining bolts and remove shifter.
6. Raise vehicle on hoist and position safety stands.
7. Remove drain plug and drain oil from transmission.
8. Remove body reinforcement in front of axle.
9. Disconnect the rear exhaust assembly from the resonator.
10. Remove four bolts retaining driveshaft to companion flange.
NOTE: The rear driveshaft yoke and, companion flange are marked so that the, driveshaft can be installed in its original position.
1989
16-20-4A Transmission, Manual-M5R2 16-20-4A
REMOVAL AND INSTALLATION (Continued)
11. Position axle stand under the front axle housing and remove forward and rear retaining nuts, and bolt plage.
12. Pull vent tube from hole in sub-frame.
13. Lower front of axle housing with axle stand and slide driveshaft out of transmission above axle housing. Let driveshaft rest on the front driveshaft support and axle assembly.
CAUTION: Use care when positioning driveshaft so not to nick, burr or contaminate driveshaft yoke or companion flange.
14. Remove catalytic converter assembly.
15. Disconnect hydraulic clutch line.
16. Disconnect electrical connectors.
17. Remove starter.
18. Position transmission jack under transmission.
19. Remove crossmember.
20. Remove bellhousing-to-engine bolts.
21. Move transmission to the rear until the input shaft clears engine flywheel. Lower transmission from vehicle.
Installation
1. Secure transmission assembly on transmission jack. Install guide studs in the engine block and raise transmission until input shaft splines are aligned with clutch disc splines.
2. Slide transmission forward on guide studs until it is positioned in the vehicle.
3. Install bellhousing-to-engine retaining bolts. Tighten to 54-67 N-m (40-50 lb.ft.).
4. Install crossmember. Tighten bolts to 47-68 N-m (35-50 lb.ft.).
5. Remove transmission jack.
6. Connect electrical connectors.
7. Connect hydraulic clutch line.
8. Install starter.
9. Install catalytic converter assembly.
10. Slide driveshaft into transmission.
NOTE: Lubricate yoke splines with Long Life Lubricant C1AZ-19590-BA or equivalent.
11. Raise axle housing with axle stand and install bushings and retaining nuts, Tighten to 92-136 N-m (68-100 ft.lb.). Remove axle stand.
1989
16-20-4B Transmission, Manual-M5R2 16-20-4B
REMOVAL AND INSTALLATION (Continued)
12. Position vent tube in hole of sub-frame.
13. Align driveshaft yoke and companion flange, and install retaining bolts. Tighten to 95-129 N-m (70-95 lb.ft.).
14. Connect exhaust pipe muffler assembly to resonator.
15. Lower vehicle.
16. Position shifter and install retaining bolts. Tighten to 24-33 N-m (18-24 lb.ft.).
17. Install console top cover.
18. Install shifter knob.
19. Connect battery ground cable.
DISASSEMBLY AND ASSEMBLY
Transmission Disassembly
1. Using a 24 mm wrench, remove transmission drain plug and drain transmission.
2. Using a 10 mm socket, remove four shift control. housing bolts and pry up gently on the housing.
3. Using a 5/32-inch punch and hammer, remove the offset lever retaining pin located in the extension housing. Retrieve offset lever retaining pin using a pencil magnet.
NOTE: If it is necessary to remove rear seal from extension housing, extension housing must remain installed to transmission case. Remove extension housing rear seal using Extension Housing Seal Remover T74P-77248- A or equivalent.