I am modifying my 06 trans into an 02-04.
Tools required: 10mm socket, 12mm socket, 14mm socket, 17 mm wrench or socket, 8mm allen socket, 12mm socket, 14mm socket, pry bar or any pry tool, snap-ring expander, 6mm, 8mm, 10mm drill bit, tap-die set. That it for now I will add the correct tap size later.
Parts required: 05-06 trans, 02-04 diff, 02-04 speed sensor, 10mm bolt.
Machine shop is required to drill the hole for the 02-04 speed sensor. I will give the size when i take it to get done Monday.
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This is the pics of the trans with all the bolt removed. Remove all the 12mm bolts and mark the 3 bracket so you will remember where they go back(not in pictures). Remove the 14mm reverse gear bolt, the speed sensor, the 4 10mm shifter assembly bolts, 3 detent bolts, ball-bearing, springs, 8mm allen bolt on the side of the trans, 14mm allen bolt on top of the trans. Mark everthing so it will make everything easy to install when done.
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You must remove the 8mm allen bolt to get the shifter assembly out.
Remove the four 10mm bolts and pry the shifter assembly up and pull it out with it in neutral.
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Remove the 14mm bolt and pry the snap-ring apart while you break the trans case seal with the pry-bar. Pry the housing apart, remove the housing and set it aside. The seal is hard so you might have to use a seal break to get it open.
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Now this is what you should see. Remove the reverse gear and it shaft(not picture) and use both hand and grab on to the mainshaft, countershaft, shift forks and pull it up all at once and set it aside.
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This what you should see with it removed. Now hold on to the differential bearing and pull it strait up, if you get it cock sideway it will not come out, try to push it back down and pull it straight up and out.
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Here the photo of what it looks like side by side, notice that the 05-06 diff is longer and will not work. I had a 02-04 base model, 02-04 diff, and 05-06 differential side by side to show you guys what the size different.
02-04 left 02-04 base model center 05-06 right
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http://s155.photobucket.com/albums/s313/acuratech23/?action=view¤t=DSC00772-1.jpg
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02-04 Left 05-06 left With ring gear already swap over to 02-04 diff.
Swap the ring gear from the 05-06 over to the 02-04 differential.
Now remove the 17 bolt that block the speed sensor hole and take the clutch case to the machine shop to get it drill outI will post more when it done.
I will post more when the machine is done with the process of enlarging the speedo hole because I don't have a drill bit that big.
Tools required: 10mm socket, 12mm socket, 14mm socket, 17 mm wrench or socket, 8mm allen socket, 12mm socket, 14mm socket, pry bar or any pry tool, snap-ring expander, 6mm, 8mm, 10mm drill bit, tap-die set. That it for now I will add the correct tap size later.
Parts required: 05-06 trans, 02-04 diff, 02-04 speed sensor, 10mm bolt.
Machine shop is required to drill the hole for the 02-04 speed sensor. I will give the size when i take it to get done Monday.
This is the pics of the trans with all the bolt removed. Remove all the 12mm bolts and mark the 3 bracket so you will remember where they go back(not in pictures). Remove the 14mm reverse gear bolt, the speed sensor, the 4 10mm shifter assembly bolts, 3 detent bolts, ball-bearing, springs, 8mm allen bolt on the side of the trans, 14mm allen bolt on top of the trans. Mark everthing so it will make everything easy to install when done.
You must remove the 8mm allen bolt to get the shifter assembly out.
Remove the four 10mm bolts and pry the shifter assembly up and pull it out with it in neutral.
Remove the 14mm bolt and pry the snap-ring apart while you break the trans case seal with the pry-bar. Pry the housing apart, remove the housing and set it aside. The seal is hard so you might have to use a seal break to get it open.
Now this is what you should see. Remove the reverse gear and it shaft(not picture) and use both hand and grab on to the mainshaft, countershaft, shift forks and pull it up all at once and set it aside.
This what you should see with it removed. Now hold on to the differential bearing and pull it strait up, if you get it cock sideway it will not come out, try to push it back down and pull it straight up and out.
Here the photo of what it looks like side by side, notice that the 05-06 diff is longer and will not work. I had a 02-04 base model, 02-04 diff, and 05-06 differential side by side to show you guys what the size different.
02-04 left 02-04 base model center 05-06 right
02-04 Left 05-06 left With ring gear already swap over to 02-04 diff.
Swap the ring gear from the 05-06 over to the 02-04 differential.
Now remove the 17 bolt that block the speed sensor hole and take the clutch case to the machine shop to get it drill outI will post more when it done.
I will post more when the machine is done with the process of enlarging the speedo hole because I don't have a drill bit that big.
