Removal and Installation

REMOVAL

HINT: Turn the touch select 2-4 switch ON.

1. DISCONNECT BREATHER HOSE
Disconnect the breather hose from the transfer.
2. RAISE VEHICLE AND DRAIN TRANSFER OIL
3. REMOVE LH AND RH FRONT EXHAUST PIPES
4. REMOVE FRONT AND REAR PROPELLER SHAFTS





5. REMOVE CROSSMEMBER
a. Support the transmission rear side with a transmission jack.
b. Remove the 4 bolts.
c. Remove the 4 bolts, nuts and crossmember.
6. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the transfer adaptor.
7. DISCONNECT VEHICLE SPEED SENSOR, TRANSFER DETECTION SWITCHES AND MOTOR ACTUATOR CONNECTORS





8. REMOVE TRANSFER
a. Support the transfer with another transmission jack.
b. Remove the 8 transfer mounting bolts.
c. Pull out the transfer from the transfer adaptor down and toward the rear.

INSTALLATION





1. RAISE VEHICLE
2. INSTALL TRANSFER
Raise the transfer and install it to the transfer adaptor with the 8 transfer mounting bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)

NOTICE: Take care not to damage the lip of the transfer adaptor rear oil seal with the transfer input shaft.

3. CONNECT VEHICLE SPEED SENSOR, TRANSFER DETECTION SWITCHES AND MOTOR ACTUATOR CONNECTORS





4. INSTALL ENGINE REAR MOUNTING
Install the engine rear mounting to the transfer adaptor with the 4 bolts.
Torque: 65 Nm (650 kgf-cm, 48 ft. lbs.)
5. INSTALL CROSSMEMBER
a. Install the crossmember with the 4 bolts and nuts.
Torque: 72 Nm (740 kgf-cm, 53 ft. lbs.)
b. Install the the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
c. Remove the transmission jacks.
6. INSTALL FRONT AND REAR PROPELLER SHAFTS
7. INSTALL LH AND RH FRONT EXHAUST PIPES





8. FILL TRANSFER OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.0 liters (1.1 US qts., 0.9 Imp. qts.)
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
9. CONNECT BREATHER HOSE
Connect the breather hose to the transfer.
Hose installation depth: 13 mm (0.51 inch) or more
10. DO ROAD TEST
Check for abnormal noises and smooth shifting.