Hi all, hope folks are enjoying the weather and getting a little off-road time with their 4WD. I am changing the clutch system on my 2003 4.0/5spd 4WD ranger. The job has progressed to the point all 6 bolts are removed from the trans and it is ready to be separated from the engine. It doesn't want to come apart and even a pry bar only gets it a half inch apart then it closes up when the pry bar is removed. Could it be that I have too much pressure on the trans with the trans jack? Any suggestions on how to pull the trans from the engine? Yes, the crossmember is removed, electrical connections unmade, and the clutch tube is removed. With the transfer case, I hammered a screwdriver between the transfer case and trans case, then worked it around the transfer case and was able to pry it to get it an inch apart, then pull it the rest of the way by hand. Do I need to do the same thing with the trans? Thanks for all hints and tips. I will post photos when the job is completed.

 

When me and my buddy did his tranny on his 94, we did not rmove the t-case from the tranny (that dont matter), yet, i do not recall having issues removing the tranny from the motor, I will ask him and come back to you today

 

The M5ODR1-HD has 9 bolts from the bell to engine. 3 of them are up high and I suspect that they are the ones that you missed. Lowering the tail of the transmission a little should allow you to see/access them.

NO!

 

I am wondering if there is a dowel pin in the rear of the engine or in the bell housing. These can get corroded and cause difficulty in removing a part. If there is a dowel pin, I"ll shoot it with PB blaster and let it soak for a while. Maybe your buddy will remember whether a dowel pin is located in the bell housing. Thanks for checking.

 

Thanks. I think this is it. I missed a top bolt. The Haynes manual says there are 6 bolts in the bellhousing and 2 bolts additional to mount the starter. However, the photo link here clearly shows a 7th bolt hole in the bellhousing, which is one of the three top bolts you mentioned. I removed two of the three top bolts. I suspect I missed on of the top corner bolts. The M50D-R1 had 8 not 9, but the R1HD has 9. THANK YOU to all who posted replies here. And Yup, there are two dowel pins, but they are blind pin holes so cannot get PB blaster to them. When I re-assemble, I will lightly coat them in anti-seize.

After working on classic mustangs for 10 years, the ranger is a whole new technology and parts list.