Removal

REMOVAL

WARNING:
- Make sure jacks and safety stands are placed properly, and hoist brackets are attached to correct position on the engine.
- Apply parking brake and block rear wheels so vehicle will not roll off stands and fall on you while working under it.

CAUTION: Use fender covers to avoid damaging painted surfaces.

1. Disconnect the negative (-) cable first, then the positive (+) cable from the battery.
2. Remove the intake air duct and air cleaner housing.





3. Remove the slave cylinder and clutch hose bracket.

NOTE:
- Do not operate the clutch pedal once the slave cylinder has been removed.
- Take care not to bend the clutch line.





4. Disconnect the starter cables and transmission ground cable.





5. Disconnect the back-up light switch connector and wire harness clamp.





6. Remove the cotter pins, then remove the steel washers, plastic washers, shift cable, and select cable from the levers.
7. Remove the cable bracket from the clutch housing.





8. Disconnect the vehicle speed sensor VSS) connector.





9. Remove the four upper transmission mounting bolts.
10. Drain transmission fluid.





11. Remove the guard bar and the splash shield.





12. Disconnect the Heated Oxygen Sensor (H02S) connector, then remove the exhaust pipe A.





13. Mark reference marks on the joint of the transfer and the propeller shaft.
14. Separate the propeller shaft from the transfer assembly.





15. Remove the cotter pins, and castle nuts, then separate the ball joints from the lower arm.
16. Remove the right damper fork bolt, then separate right damper fork and damper.
17. Pry the right driveshaft out of the differential, and pry the left driveshaft out of the intermediate shaft.
18. Pull out the inboard joint, and remove the right and left driveshaft.





19. Tie plastic bags over the driveshaft ends. Coat all precision finished surfaces with clean engine oil.





20. Remove the intermediate shaft.
21. Tie plastic bags over the both ends of the intermediate shaft. Coat all precision finished surfaces with clean engine oil.





22. Remove the rear engine stiffener and clutch housing cover.





23. Remove the right front mount/bracket.





24. Place a jack under the transmission, raise it just enough to take it off of the mounts, then remove the transmission mount bracket and transmission mount.





25. Remove the transmission mounting bolts and the rear engine mounting bolts.
26. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmission jack.

NOTE: Take care not to bend the clutch line.





27. Remove the starter motor and hose clamp from the transmission housing.





28. Remove the release fork boot, release bearing, and release fork from the clutch housing.