Transmission Assembly Removal and Installation
REMOVAL
NOTE: Before remove transmission and transfer assembly from vehicle, change the transfer mode to 2WD using push button on dash panel.
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Remove transfer control lever knob (1) and disconnect wiring harness connectors, then remove front console (2).
4. Disconnect shift lock cable from the selector lever assembly side.
5. Disconnect wiring harness connectors.
6. Disconnect shift control rod from the selector lever assembly side.
7. Remove selector lever assembly (3).
8. Remove transfer control lever (4).
9. Remove transfer protector (5).
10. Remove rear propeller shaft (6).
11. Remove front propeller shaft (7).
12. Remove harness protector (8).
13. Support transfer case with a jack and remove two rear mount nuts (9) from the 3rd crossmember side.
14. Remove eight third crossmember bolts and third crossmember (10)
15. Remove right torsion bar from fourth crossmember. (TOD model)
16. Remove front exhaust silencer mounting nuts.
17. Disconnect two oxygen sensor connectors from the transmission harness.
18. Remove left catalytic converter assembly (11).
19. Loosen right catalytic converter nuts to exhaust manifold. (except TOD model)
NOTE: This will make the next steps easier. Remove right catalytic converter assembly. (TOD model)
20. Disconnect transmission oil cooler pipe (12) from A/T side.
21. Remove oil pipe clamp from torque converter housing bracket.
22. Loosen oil pipe clamp bolt at the engine mount side.
23. Remove starter (13).
24. Disconnect fuel pipe clamp bracket from transmission side.
25. Disconnect transmission harness connectors (14) from transmission, transfer, and catalytic converter.
26. Remove flywheel under covers (3 pieces) (15) from transmission case.
27. Lower the front of the transmission a little, then remove flywheel torque converter fixing bolts (6 pieces) (16) by turning crankshaft.
28. Support the transmission with a transmission jack, and hoist engine with a chain block.
29. Remove engine transmission fixing bolts (17).
30. Remove transmission assembly (18).
INSTALLATION
1. Slowly raise transmission jack until front of the transmission is aligned with rear of the engine, then install transmission assembly.
2. Tighten engine transmission bolts, to the specified torque.
3. Support transfer case with a jack, and remove the transmission jack.
4. Install flywheel torque converter bolts (6 pieces) by turning crankshaft.
Torque: 54 Nm (40 ft. lbs.)
5. Install the flywheel undercover (3 pieces), and tighten the bolts to the specified torque.
Torque: 8 Nm (69 inch lbs.)
6. Install the starter, and tighten the bolts to the specified torque.
Torque: 40 Nm (30 ft. lbs.)
7. Connect transmission harness connectors to transmission, transfer, and catalytic converter.
8. Connect fuel pipe bracket to transmission side.
9. Install transmission oil cooler pipe to transmission.
Torque: 54 Nm (40 ft. lbs.)
10. Install oil pipe clamp to torque converter housing bracket.
11. Tighten oil pipe clamp bolt at engine mount side.
12. Install right catalytic converter, tighten to the specified torque.
Torque: 67 Nm (49 ft. lbs.)
13. Install left catalytic converter assembly, and tighten the bolts to the specified torque.
Exh. pipe to exhaust manifold 67 Nm (49 ft. lbs.)
Exh. pipe flange bolt 47 Nm (32 ft. lbs.)
14. Connect two oxygen sensor connectors to the transmission harness.
15. Install front exhaust silencer mounting nuts.
16. Install left torsion bar assembly to fourth crossmember.
17. Install third crossmember, and tighten the bolts to the specified torque.
Torque: 50 Nm (37 ft. lbs.)
18. Install rear mount nuts, and tighten the bolts to the specified torque.
Torque: 40 Nm (30 ft. lbs.)
19. Remove the jack from the transfer case.
20. Install harness protector.
21. Install the front propeller shaft, and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)
22. Install the rear propeller shaft, and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)
23. Install the transfer protectors, and tighten the bolts to the specified torque.
Torque: 37 Nm (27 ft. lbs.)
24. Install the transfer control lever.
25. Install the selector lever assembly.
26. Connect the shift control rod to selector lever assembly.
27. Connect the wiring harness connectors.
28. Connect the shift lock cable to selector lever assembly.
29. Connect the wiring harness connectors to front console.
30. Install the front console.
31. Install the transfer control lever knob.
32. Connect the battery ground cable.
33. Install the engine hood.