Removal and Installation

REMOVAL





1. REMOVE TRANSMISSION SHIFT LEVER
a. Remove the transmission and transfer shift lever knobs.
b. Remove the 4 bolts and shift lever boot retainer.
c. Remove the transmission and transfer shift lever boot.
d. Turn over the dust boot.
e. Using a cloth, cover the shift lever cap.
f. While, pressing down on the shift lever cap, rotate it counterclockwise to remove.
g. Pull out the transmission shift lever.

HINT: At the time of installation, please refer to the following item. Apply MP grease to the tip of the shift lever.

2. REMOVE TRANSFER SHIFT LEVER





3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
5. DISCONNECT VEHICLE SPEED SENSOR, BACK-UP LIGHT SWITCH, TRANSFER 4WD POSITION SWITCH AND TRANSFER L4 POSITION SWITCH CONNECTOR





6. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE
a. Remove the clip.
b. Remove the 4 bolts, release cylinder and line.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





7. REMOVE FRONT EXHAUST PIPE
a. Disconnect the oxygen sensor connector.
b. Remove the 2 bolts and converter rear flange retainer.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





c. Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)

HINT: At the time of installation, please refer to the following item. Replace the used gaskets and nuts with new ones.





8. REMOVE STARTER
a. Disconnect the connector.
b. Remove the nut and disconnect the terminal.





c. Remove the 2 bolts and starter.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





9. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
10. SUPPORT TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.





11. REMOVE CROSSMEMBER
a. Disconnect the wire harness clamp from the crossmember.
b. Remove the 4 set bolts of the engine rear mounting on the crossmember.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
c. Remove the 4 nuts, washers and bolts.
Torque: 72 Nm (734 kgf-cm, 53 ft. lbs.)
d. Remove the crossmember.





12. REMOVE TRANSMISSION WITH TRANSFER
a. Remove the 6 transmission mounting bolts from the engine.
Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.)
b. Disconnect the wire harness from the clamps of the transmission and transfer.
c. Pull out the transmission with the transfer down and toward the rear.

NOTICE: Be careful not to damage the PS turn pressure tube and front differential companion flange.

13. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)





14. REMOVE TRANSFER FROM TRANSMISSION
a. Remove the 8 transfer adaptor rear mounting bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
b. Pull the transfer straight up and remove it from the transmission.

HINT: Take care not to damage the adaptor rear oil seal with the transfer input gear spline.

HINT: At the time of installation, please refer to the following item. Apply MP grease to the lip of the adaptor oil seal.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, do the road test.