On-Vehicle Service
TRANSMISSION
REMOVAL
Preparation:
- Remove engine hood.
- Disconnect battery negative (-) cable.
1. Exhaust and transfer protectors
- Remove three exhaust and transfer protectors.
2. Exhaust pipe and heat protector
- Disconnect oxygen sensor connector from the transmission harness.
- Remove the three way catalytic converter, center and left front exhaust pipe.
- Remove the harness heat protector.
3. Slave cylinder, heat protector, dust cover (1) and (2).
- Remove the heat protector.
- Remove the slave cylinder.
- Remove the dust cover (1) and (2).
4. Rear propeller shaft
- Remove the rear propeller shaft.
NOTE: Apply alignment marks on the flange at the both front and rear side.
5. Transmission harness connectors
- Disconnect the reverse lamp switch, 4WD indicator switch, 1-2 and 3-4 indicator switch harness connectors.
- Disconnect the speed sensor harness connector.
- Remove two transmission harness clamps from the transmission case.
6. Engine rear mount nuts
- Support the transfer case with a jack.
- Remove two engine rear mount nuts.
7. Third crossmember
- Remove eight third crossmember bolts.
8. Engine rear mount
- Remove two engine rear mount bolts.
- Remove the rear mount from the transmission.
9. Front crossmember
- Remove four; front crossmember bolts.
- Remove the front crossmember from the frame.
10. Front propeller shaft
- Remove the front propeller shaft.
NOTE: Apply alignment marks on the flange at both the front and rear sides.
11. Gear control lever.
- Remove the gear control lever knob.
- Remove the front console and Engine Control Module (ECM) cover.
- Remove the grommet assembly.
- Remove the transmission control lever and transfer control lever.
- Support the transmission with a transmission lack and then remove jack from the transfer case side.
12. Flywheel under cover bolts
- Remove three flywheel under cover bolts.
13. Transmission assembly
- Use the remover for disconnect the clutch release bearing from the clutch pressure plate.
Clutch release bearing remover : J39207
Release bearing disconnection
1. Pull the shift fork toward the transmission to press the clutch release bearing against the clutch.
2. Insert the clutch release bearing remover between the wedge collar and the release bearing.
3. Turn the remover to separate the release bearing.
NOTE: Be sure not to insert the remover between the wedge collar and the clutch.
- Remove the transmission retaining nuts and bolts.
- Remove the transmission from the vehicle.
INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points:
13. Transmission assembly
- Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline.
- Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine.
he slope of the engine and the transmission must be the same.
- Align the top gear shaft spline with the clutch driven plate spline.
- Install the transmission to the engine.
Tighten the transmission nuts and bolts.
- Apply a force of 59-78N (13.2 - 17.61b) to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing.
NOTE: A click sound is heard when the release bearing and the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing the tip of the shift fork toward the engine while applying a force of about 25N (5.5 lb). If the shift fork will not move, then they are securely engaged.
12. Flywheel under cover bolts
- Install three flywheel under cover bolts.
11. Gear control lever
- Install the transmission control lever and transfer control lever.
- Install the grommet assembly.
- Install the front console and Engine Control Module (ECM) cover.
- Install the gear control lever knob.
- Support the transfer case with a jack and then remove the transmission jack from transmission side.
10. Front propeller shaft
- Install the front propeller shaft.
Torque : 63 (46) N.m (lb.ft)
9. Front crossmember
- Install the front crossmember.
Torque : 78 (58) N.m (lb.ft)
8. Engine rear mount
- Install the engine rear mount.
Torque : 41 (30) N.m (lb.ft)
7. 3rd crossmember
- Install the 3rd crossmember.
Torque : 50 (37) N.m (lb.ft)
6. Engine rear mount nuts
Torque : 50 (37) N.m (lb.ft)
- Remove the transmission jack.
5. Transmission harness connectors.
- Install two transmission harness clamps to the transmission case.
- Connect the speed sensor harness connector.
- Connect the reverse lamp switch, 4WD indicator switch, 1-2 and 3-4 indicator switch harness connectors.
4. Rear propeller shaft
- Install the rear propeller shaft.
Torque : 63 (46) N.m (lb.ft)
3. Slave cylinder, heat protector, dust cover (1) and (2)
- Apply the grease to top hole portion of the shift fork.
- Install the clutch dust cover (1) and (2) to the clutch housing.
Torque : 6 (52) N.m (lb.in)
- Install the slave cylinder heat protector to the slave cylinder.
2. Exhaust pipe and heat protector
- Install the harness heat protector.
- Install the three way catalytic converter, center and left front exhaust pipes.
Torque:
Exh.pipe-exh.manifold : 67 (49) N.m (lb.ft)
Center pipe front side bolt : 50 (37) N.m (lb.ft)
Three way catalytic converter bolt : 34 (25) N.m (lb.ft)
- Connect oxygen sensor connector to the transmission harness.
1. Exhaust and transfer protectors
Torque : 37 (27) N.m (lb.ft)
- Connect battery negative (-) cable.
Install engine hood.