Transmission Removal and Installation

Removal and Installation

REMOVAL





CAUTION: When removing the M/T assembly from engine, first remove the crankshaft position sensor (OBD) from the M/T assembly. Be careful not to damage sensor edge.

2WD Model
1. Remove battery negative terminal.





2. Remove shift lever.
3. Remove crankshaft position sensor (OBD) from upper side of transmission case.
4. Remove operating cylinder from transmission.
5. Disconnect vehicle speed sensor, back-up lamp switch, heated oxygen sensor (rear) and Park/Neutral Position (PNP) switch harness connectors.
6. Remove starter motor
7. Remove propeller shaft.
^ Insert plug into rear oil seal after removing propeller shaft.
^ Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft.

8. Remove gussets from transmission or engine.
9. Remove exhaust tube mounting bracket from transmission.
10. Support manual transmission with a jack.
11. Remove rear mounting member.
12. Lower manual transmission.

WARNING: Support manual transmission together with transfer while removing it.





4WD Model





1. Disconnect the battery negative terminal.
2. Remove shift lever from transmission and control lever from transfer.
3. Remove clutch operating cylinder from transmission.
4. Disconnect the vehicle speed sensor, back-up lamp switch, heated oxygen sensor (rear) and Park/Neutral Position (PNP) switch harness connectors.
5. Remove the starter motor.
6. Remove front and rear propeller shafts.
^ Insert plug into rear oil seal after removing propeller shaft.
^ Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft.

7. Remove exhaust tube mounting bracket from transmission.
8. Remove front exhaust tubes and center pipe.
9. Remove the torsion bars and mounts.
10. Remove the rear torsion bar cross member.
11. Remove the gussets from the transmission or engine.
12. Support the manual transmission with a jack.
13. Remove rear mounting member.
14. Lower manual transmission.

WARNING: Support manual transmission together with transfer while removing it.

15. Remove crankshaft position sensor (OBD) from upper side of transmission case.
16. Remove transmission bolts.

WARNING: Support manual transmission together with transfer while removing it.

INSTALLATION








^ Tighten the bolts securing the transmission to the specified torques in the chart.
^ Installation is in the reverse order of removal.