Unit Removal and Installation

TRANSMISSION AND ASSOCIATED PARTS

REMOVAL

NOTE: Before remove transmission and transfer assembly from vehicle, change the transfer mode to 2WD using push button on dash panel.

1. Disconnect battery ground cable.





2. Remove transfer protector (4x4) and fairing plate.





3. Remove rear propeller shaft and front propeller shaft (4x4).





NOTE: Apply alignment marks on the flange at both front and rear sides.





4. Remove center exhaust pipe.





5. Remove fuel pipe heat protector and clip.
6. Disconnect transmission harness connector and clip. Connector: Adapter case, mode switch, main case, magnetic sensor, transfer switch (4x4), 2-4 actuator (4x4) and car speed sensor.





7. Remove harness heat protector.





8. Support transmission with a jack. Remove rear mount nuts from 3rd crossmember.
9. Remove third crossmember.
10. Disconnect transmission oil cooler pipes from A/T side.





11. Remove oil pipe clamp and bracket from the converter housing.
12. Loosen oil cooler pipe clamp bolt at the engine mount side.





13. Remove select cable by disconnecting inner cable from select lever and removing outer cable with bracket.
14. Remove starter.
15. Remove flywheel under covers from the transmission and engine.





16. Remove transfer control lever fixing bolts and push up transfer control lever.





17. Remove flywheel-torque converter fixing bolts (6 pieces) by turning crankshaft.
18. Remove engine-transmission fixing bolts.
19. Pull out transmission from the engine.

INSTALLATION
1. Slowly raise transmission jack until front of the transmission is aligned with rear of the engine. Join the transmission to the engine.





2. Tighten engine-transmission bolts as shown in the figure.





3. Align the flywheel-torque converter bolt boss with flywheel hole by turning the torque converter. Install flywheel-torque converter bolts (6 pieces) by turning the crankshaft.

Torque: 54 Nm (40 ft. lbs.)





4. Install transfer control lever on the transfer case.
5. Install flywheel under covers to the transmission and engine.

Torque: 8 Nm (69 Ft. lbs.)

6. Install starter.

Torque: 40 Nm (30 Ft. lbs.)





7. Install select cable by connecting inner cable to select lever and installing outer cable with bracket.
8. Connect transmission oil cooler pipes to A/T.

Torque: 45 Nm (33 Ft. lbs.)





9. Install oil cooler pipe clamp and bracket to the converter housing.
10. Tighten oil cooler pipe clamp bolt at the engine mount side.
11. Install third crossmember.

Torque: 50 Nm (37 Ft. lbs.)





12. Install rear mount nuts.

Torque: 40 Nm (30 Ft. lbs.)





13. Install harness heat protector.

Torque: 6 Nm (52 Ft. lbs.)

14. Connect transmission harness connector and clip. Connector: Adapter case, mode switch, main case, magnetic sensor, transfer switch, 2-4 actuator and car speed sensor.





15. Connect fuel pipe to transmission side.





(4x4)





(4x2)





16. Install fuel pipe heat protector and clip.





17. Install center exhaust pipe.

Torque: 43 Nm (32 Ft. lbs.)

18. Install front propeller shaft & rear propeller shaft.

Torque: 63 Nm (46 ft. lbs.)





19. Install transfer protector and fairing plate.