Removal and Installation
REMOVAL AND INSTALLATIONNote: Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.
Important Operations - Removal
Connections
Remove the clutch return spring, the clutch control cable, the back up light switch connector, and the speedometer cable from the transmission.
Battery
1. Disconnect the battery cable (1) and the grounding cable (2) from the battery terminals.
2. Remove the battery clamp (3). Take care not to accidentally short the battery with the spanner or some other tool.
3. Remove the battery.
4. Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
Engine Hood
Apply setting marks to the engine hood (1) and the engine hood hinges (2) before removing the engine hood. This will facilitate reinstallation of the engine hood to its original position.
Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the front console from the floor panel.
3. Pull the gear shift lever grommet (1) and the dust cover (2) to the top of the gear shift lever.
4. Remove the gear shift lever cover bolt (3).
5. Remove the gear shift lever (4).
Note: Cover the quadrant box or extension housing hole to prevent the entry of foreign material into the transmission.
Transfer Change Lever
Perform this procedure after removing the gear shift lever.
1. Place the transfer change lever in the "H" position.
2. Pull the transfer change lever grommet (1) and the dust cover (2) to the top of the transfer change lever.
3. Remove the retainer bolts (3).
4. Remove the transfer change lever (4) along with the retainer and the ball seat cover.
Note: Cover the quadrant box or extension housing hole to prevent the entry of foreign material into the transmission.
Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the vehicle.
3. Remove the wheels from the vehicle.
Transmission and Transfer Case Oil Draining
1. Remove the transmission oil drain plug (1).
2. Remove the transfer case oil drain plug (2).
Transfer Case Protector
Remove the transfer case protector (1) from the transmission mounting member (2) and the side member (3).
Rear Propeller Shaft (Single Shaft Type)
1. Remove the propeller shaft flange yoke at the drive pinion side (1).
2. Remove the propeller shaft from the transmission main shaft spline (2).
Rear Propeller Shaft (Dual Shaft Type)
1. Remove the propeller shaft flange yoke at the drive pinion side (1).
2. Remove the 2nd propeller shaft flange yoke bolts (2) at the center bearing side.
3. Remove the center bearing bolts (3).
4. Remove the 1st propeller shaft (4) with the center bearing.
Pull the 1st propeller shaft toward the rear of the vehicle until the spline yoke is free of the transmission main shaft.
Front Propeller Shaft
Remove the splined yoke flange bolt at the transfer case side.
Do not allow the splined yoke to fall away from the front propeller shaft.
If the splined yoke should fall away from the front propeller shaft align the setting marks (3) on the splined yoke (1) and the propeller shaft (2) to reassemble the two parts. The setting marks are punched circles approximately (3) mm (0.12 in) in diameter.
Starter Motor
Remove the starter motor from the engine rear plate.
Exhaust Pipe
1. Remove the exhaust pipe bracket (1) from the transmission case.
2. Disconnect the front exhaust pipe from the exhaust manifold and the 2nd exhaust pipe (2).
Engine Lifting Hanger
1. Attach the engine lifting hanger to the rear portion of the exhaust manifold.
2. Attach the lifting wire to both ends of the engine lifting hanger.
Transmission with Transfer Case
1. Support the transmission with a transmission jack
2. Remove the engine rear mounting nuts (2).
3. Loosen the mounting member bolts (3).
4. Remove the mounting member from the side members (4).
5. Remove the transmission with the transfer case from the engine.
1) Remove the transmission nuts and bolts from the engine rear plate.
2) Carefully pull the transmission with the transmission jack toward the rear of the vehicle.
3) Operate the transmission jack to slowly lower the transmission.
Important Operations - Installation
Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points during the installation procedure.
Transmission with Transfer
1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline.
2. Slowly raise the transmission jack until the front of the transmission is aligned with the rear of the engine. The slope of the engine and the transmission must be the same.
3. Align the top gear shaft spline with the clutch driven plate spline.
4. Install the transmission to the engine. Tighten the transmission nuts and bolts to the specified torque.
Transmission Nut and Bolt Torque: 3.8 ± 0.8 (27.5 ± 5.8/37.2 ± 7.8) kg.m (lb.ft/N.m)
5. Install the mounting member (1) to the mounting rubber (2).
6. Tighten the mounting member nuts (3) to the specified torque.
Mounting Rubber Nut Torque: 8.5 ± 0.5 (61.5 ± 3.6/83.3 ± 4.9) kg.m (lb.ft/N.m)
7. Install the mounting member to the side members.
8. Tighten the mounting member bolts to the specified torque.
Mounting Member Bolt Torque: 3.8 ± 1.0 (27.1 ± 7.2/36.8 ± 98) kg.m (lb.ft/N.m)
9. Tighten the engine mounting rubber nuts to the specified torque.
Engine Mounting Rubber Nut Torque: 4.2 ± 0.5 (30.4 ± 3.6/41.2 ± 4.9) kg.m (lb.ft/N.m)
Starter Motor
1. Install the starter motor to the engine rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque: 8.8 ± 1.9 (63.3 ± 16.6/85.8 ± 18.6) kg.m (lb.ft/N.m)
Front Propeller Shaft
1. Connect the propeller shaft flange yoke to the matching flange.
2. Tighten the propeller shaft flange yoke bolt to the specified torque.
Propeller Shaft Flange Yoke Bolt Torque: 6.4 ± 0.4 (46.3 ± 2.90/62.7 ± 3.92) kg.m (lb.ft/N.m)
Note: If the splined yoke and the front propeller shaft have accidentally separated, align their setting marks and recouple them.
Rear Propeller Shaft (Single Shaft Type)
1. Insert the splined yoke (1) with the propeller shaft into the transmission main shaft spline (2).
2. Install the propeller shaft flange yoke (3) to the drive pinion side.
3. Tighten the propeller shaft flange yoke bolt to the specified torque.
Propeller Shaft Flange Yoke Bolt Torque: 6.4 ± 0.4 (46.3 ± 2.90/62.7 ± 3.92)kg.m (lb.ft/N.m)
Rear Propeller Shaft (Dual Shaft Type)
1. Place the center bearing (1) together with the 1st propeller shaft (2) on the No.3 crossmember (3).
2. Insert the splined yoke (4) into the transmission main shaft spline (5).
3. Tighten the center bearing retainer bolts (6) to the specified torque.
Center Bearing Retainer Bolt Torque: 6.2 ± 0.2 (44.8 ± 1.5/60.8 ± 1.96) kg.m (lb.ft/N.m)
4. Connect the 2nd propeller shaft (7) center coupling side (8) and drive pinion side (9).
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Coupling Bolt Torque: 6.4 ± 0.4 (46.3 ± 2.90/62.7 ± 3.92) kg.m (lb.ft/N.m)
Transfer Case Protector
1. Install the transfer case protector (1) to the mounting member (2) and the side members (3).
2. Tighten the transfer case protector bolts to the specified torque.
Transfer Case Protector Bolt Torque: 3.7 ± 1.0 (26.8 ± 7.2/36.3 ± 9.8) kg.m (lb.ft/N.m)
Gear Shift Lever
1. Replenish the transmission case and the transfer case with the specified engine oil
Transmission and Transfer Case Oil
Transmission Case 2.95 (3.13) lit(qt)
Transfer Case 1.45 (153) lit(qt)
2. Install the gear shift lever (1) to the transmission case.
3. Tighten the gear shift lever cover (2) bolts to the specified torque.
Shift Lever Cover Bolt Torque: 2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 1.96) kg.m (lb.ft/N.m)
4. Install the dust cover (3) and the grommet (4).
Transfer Change Lever
1. Insert the transfer change lever (1) into the transfer side case.
2. Install the ball seat cover along with the change lever retainer.
3. Tighten the change lever retainer bolts to the specified torque.
Change Lever Retainer Bolt Torque: 2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 1.96) kg.m (lb.ft/N.m)
4. Install the dust cover (3) and the grommet (4).
Engine Hood
Align the setting marks (applied at removal) on the engine hood (1) and the engine hood hinges (2) to install the engine hood.