Removal and Installation

Transmission (With Transfer Case)








Transmission And Associated Parts
Removal
1. Remove engine hood.
2. Place selector lever in neutral.
3. Disconnect battery ground cable.





4. Raise the vehicle and support it on jack stands. Disconnect shift control rod from the selector lever assembly side.
5. Remove transfer control lever knob (1).
6. Remove rear console (2).
7. Remove center console (3).
8. Remove two PCM covers (4).





9. Disconnect shift lock cable from the selector lever assembly side.
10. Disconnect wiring harness connectors and remove selector lever assembly (5).





11. Disconnect ground cable and remove transfer control lever (6).





12. Remove front propeller shaft assembly (7).
13. Disconnect rear propeller shaft (8) from the transfer case flange.





14. Disconnect seat belt tension rod (9) from the floor.
15. Support transfer case with a jack and remove two rear mount nuts (10) from the third crossmember.








16. Disconnect harness clip and bracket from the third crossmember side.
17. Remove eight third crossmember bolts and third crossmember (11).





18. Disconnect two oxygen sensor connectors of the left catalytic converter from the transmission harness.
19. Remove left catalytic converter assembly (12).
20. Remove exhaust silencer assembly (13).
21. Loosen right catalytic converter nuts to exhaust manifold.

Notice: This will make the next steps easier.

22. Disconnect two oxygen sensor connectors of the right catalytic converter from the transmission harness.
23. Disconnect transmission oil cooler pipe (14) from the transmission case.





24. Remove oil pipe clamp bracket from the torque converter housing.
25. Loosen oil pipe clamp bolt at right engine mount side.





26. Disconnect fuel pipe clamp bracket from the transmission side.
27. Remove harness protector (15).
28. Disconnect transmission harness connectors from the transmission and transfer case.
29. Remove front crossmember (16).
30. Remove starter (17).
31. Remove under covers (3 pieces) (18) from the transmission case.





32. Remove flex plate torque converter fixing bolts (6 pieces) (19) by turning crankshaft.
33. Support the transmission with a transmission jack and remove the jack from the transfer case.
34. Remove engine transmission fixing bolts (20).
35. Remove transmission assembly with transfer case (21).

Installation
To install, follow the removal steps in the reverse order, noting the following points:
1. Slowly raise transmission jack until front of the transmission is aligned rear of the engine, then install transmission assembly with transfer case.





2. Tighten engine transmission fixing bolts to the specified torque.
3. Support transfer case with a jack, and remove the transmission jack.





4. Install flex plate torque converter bolts (6 pieces) by turning crankshaft.
Torque: 54 Nm (40 ft. lbs.)

Notice: Do not reuse the flex plate torque converter bolt.

5. Install under cover (3 pieces), and tighten the bolts to the specified torque.
Torque: 8 Nm (69 inch lbs.)
6. Install starter, and tighten the bolts to the specified torque.
Torque: 40 Nm (30 ft. lbs.)
7. Install front crossmember, and tighten the bolts to the specified torque.
Torque: 78 Nm (58 ft. lbs.)
8. Connect transmission harness connectors to the transmission and transfer case.
9. Install harness connector.





10. Connect fuel pipe clamp bracket to the transmission side.
11. Install transmission oil cooler pipe to the transmission, and tighten the nuts to the specified torque.
Torque: 44 Nm (33 ft. lbs.)
12. Install oil pipe clamp bracket to the torque converter housing.
13. Tighten oil pipe clamp bolt at right engine mount side.
14. Tighten right catalytic converter bolts to the specified torque.
Torque: 67 Nm (49 ft. lbs.)
15. Connect two oxygen sensor connectors of the right catalytic converter to the transmission harness.
16. Install left catalytic converter assembly, and tighten the bolts to the specified torque.
Exhaust pipe to exhaust manifold: 67 Nm (49 ft. lbs.)
Exhaust pipe flange bolt: 43 Nm (32 ft. lbs.)
17. Connect two oxygen sensor connectors of the left catalytic converter to the transmission harness.
18. Install exhaust silencer assembly.
19. Install third crossmember, and tighten the bolts to the specified torque.
Torque: 50 Nm (37 ft. lbs.)
20. Install rear mount nuts, and tighten the nuts to the specified torque.
Torque: 50 Nm (37 ft. lbs.)
21. Remove the jack from the transfer case.








22. Connect harness clip and bracket to the third crossmember.
23. Install rear propeller shaft, and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)
24. Install seat belt tension rod to the floor.
25. Install front propeller shaft, and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)





26. Install transfer control lever and connect ground cable.
27. Connect wiring harness and install selector lever assembly.
28. Connect shift control rod to the selector lever assembly.
29. Connect shift lock cable to the selector lever assembly.
30. Install two PCM covers.
31. Install center console assembly. Refer to Shift Cable, A/T; Adjustments.
32. Install rear console assembly.
33. Install transfer control lever knob.
34. Connect battery ground cable.
35. Install engine hood.