Transmission Removal

Transmission Assembly





Transmission and Associated Parts

Removal
1. Disconnect battery ground cable.








2. Remove rear propeller shaft and front propeller shaft (4x4).

NOTE: Apply alignment marks on the flange at both front and rear sides.





3. Loosen the nuts fixing front exhaust pipe to exhaust manifold but do not remove the nuts.





4. Remove fuel pipe heat protector and clip.





5. Disconnect fuel pipe bracket from transmission side.

Fuel hose connector removal procedure
If removal of the fuel hose connector is required for transmission servicing and/or replacement, follow the steps.

NOTE:

Part 1:

Part 2:

^ An O-ring is used as a seal between the fuel pipe and the connector. Take care not to damage the contact surfaces during the removal procedure. Do not allow the surface to become contaminated with dirt or other foreign material.
^ Perform the entire removal procedure with your hands. Do not use tools.

Separating the connector and fuel pipe
1. Clean the fuel pipe and connector to remove mud and other dirt.





2. For removal of the quick connector, hold the quick connector in one hand, and pull out the connector with the other hand while pressing the square relieve button of the connector, as illustrated.





NOTE: Do not use tools of any kind. Only use bare hands when disconnecting the connector. Use a lubricant (light oil) and/or push and pull the connector until the pipe is disconnected.
Cover the connectors that was removed with a plastic bag, to prevent dust or rain water from entering.

Reuse of Quick-Connector





^ Replace the port and connector if scratch, dent or crack is found.
^ Remove any dirt build up on the port when installing the connector. Replace the connector, if there is any forms of rust, dent, scratch.
^ After cleaning the port, insert it straight into the connector until it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked.

Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe assembly easier. The pipe assembly should take place immediately after applying oil (to prevent dust from sticking to the pipe surface - which may decrease sealing ability).

Part 1:

Part 2:

6. Disconnect transmission harness and ECGI harness connector and clip.
Connector: Output revolution sensor, input revolution sensor, transmission wire, neutral start switch (mode switch), H-L neutral switch (4x4), oil temperature sensor, 4WD switch (4x4), motor actuator (4x4) and car speed sensor.





7. Remove harness heat protector.





8. Remove transfer case assembly from transmission.
^ Disconnect breather hose from transfer case assembly.
9. Support transmission with a jack. Remove rear mount nuts from transmission cross member.





4x2





4x4





10. Remove transmission crossmember.
11. Disconnect transmission oil cooler pipes from A/T side.





12. Remove oil pipe clamp and bracket from the converter housing.
13. Loosen oil cooler pipe clamp bolt at the engine mount side.





14. Remove select cable by disconnecting inner cable from select lever and removing outer cable with bracket.
15. Pull out oil level gage and remove filler tube.
16. Remove starter.





17. Remove under covers from the transmission and engine.





18. Remove flex plate torque converter fixing bolts (6 pieces) by turning crankshaft.

NOTE: Replace used bolts with new fixing bolts for reassembly.

19. Remove engine transmission fixing bolts.
^ Disconnect the breather hose.
20. Pull out transmission from the engine.

NOTE: Keep the oil pan downward. Be careful not to let torque converter slide out.

21. Remove the rear mounting rubber.