Installation

NOTE: To install, follow the removal steps in the reverse order, noting the following points:





1. Transmission assembly:(13)
a. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline.
b. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine. The slope of the engine and the transmission must be the same.





c. Align the top gear shaft spline with the clutch driven plate spline.





d. Install the transmission to the engine. Tighten the transmission nuts and bolts.





e. Apply a force of 59-78 N (13.2 - 17.6 lbs.) 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 side while applying a force of about 25 N (5.5 lbs.). If the shift fork will not move, then they are securely engaged.

2. Flywheel under cover bolts.(12) Install three Flywheel under cover bolts.
3. Gear control lever:(11)
a. Install the transmission control lever and transfer control lever.
b. Install the grommet assembly.
c. Install the front console assembly.
d. Install the gear control lever knob.
e. Support the transfer case with a jack and then remove the transmission jack from transmission side.
4. Front propeller shaft.(10) Install the front propeller shaft.
^ Torque 63 Nm (46 ft. lbs.).
5. Front crossmember.(9) Install the front crossmember.
^ Torque 78 Nm (58 ft. lbs.).
6. Engine rear mount.(8) Install the engine rear mount.
^ Torque 41 Nm (30 ft. lbs.).
7. Center crossmember.(7) Install the center crossmember.
^ Torque 50 Nm (37 ft. lbs.).
8. Engine rear mount nuts.(6) Remove the transmission jack.
^ Torque 50 Nm (37 ft. lbs.).
9. Transmission harness connectors:(5)
a. Install bracket and two transmission harness clamps to the transmission case.
b. Connect the speed sensor harness connector.
c. Connect the reverse lamp switch, 4WD indicator switch, 1-2 and 3-4 indicator switch harness connectors.
10. Rear propeller shaft.(4) Install the rear propeller shaft.
^ Torque 63 Nm (46 ft. lbs.).





11. Slave cylinder, heat protector, dust cover (1) and (2):
a. Apply the grease to top hole portion of the shift fork.
b. Install the slave cylinder.
^ Torque 43 Nm (32 ft. lbs.).
c. Install the clutch dust cover (1) and (2) to the clutch housing.
^ Torque 6 Nm (52 inch lbs.).
d. Install the slave cylinder heat protector to the slave cylinder.
12. Exhaust pipe and heat protector:(2)
a. Install the harness heat protector.
b. Install right front exhaust pipe and catalytic converter assembly.
^ Exhaust pipe-exhaust manifold 67 Nm (49 ft. lbs.).
^ Exhaust pipe flange bolt 43 Nm (32 ft. lbs.).
c. Connect four oxygen sensor connectors to the transmission harness.
13. Transfer protector.(1)
^ Torque 37 Nm (27 ft. lbs.).
a. Connect battery negative ( - ) cable.
b. Install engine hood.