Removal and Installation
Part 1 Of 2:
Part 2 Of 2:
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) (4X4) and disconnect wiring harness connectors, then remove front console (2).
4. Remove selector lever assembly (3).
5. Remove transfer control lever (4).
7. Disconnect shift control rod front the selector lever assembly side.
8. Remove rear propeller shaft (6).
9. Remove front propeller shaft (7).
10. Remove harness protector (8).
11. Support transfer case (4X4) or transmission (4X2) with a jack and remove two rear mount nuts (9) from the 3rd crossmember side.
12. Remove eight third crossmember bolts and third crossmember (10).
13. Remove right torsion bar from fourth crossmember. (TOD model)
14. Remove front exhaust silencer mounting nuts.
15. Disconnect two left side oxygen sensor connectors from the transmission harness.
16. Remove left catalytic converter assembly (11).
17. 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)
18. Disconnect transmission oil cooler pipe (12) from A/T side.
19. Remove oil pipe clamp from torque converter housing bracket.
20. Loosen oil pipe clamp bolt at the engine mount side.
21. Remove starter (13).
22. Disconnect fuel pipe clamp bracket from transmission side.
23. Disconnect transmission harness connectors (14) from transmission, transfer, and catalytic converter.
24. Remove front crossmember (16).
25. Remove under covers (3 pieces) (17) from transmission case.
26. Remove flex plate torque converter fixing bolts (6 pieces) (18) by turning crankshaft.
27. Support the transmission with a transmission jack and hoist engine with a chain block.
28. Remove engine transmission fixing bolts (19).
29. Remove transmission assembly with transfer case (4X4)/extension assembly (4X2) (20).
30. Remove transfer case/extension assembly from the transmission assembly, if necessary.
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.)
NOTE: Do not reuse the flex plate torque converter bolt.
5. Install the undercover (3 pieces), and tighten the bolts to the specified torque.
Torque: 8 Nm (69 inch lbs.)
6. Install front crossmember.
Torque: 78 Nm (58 ft. lbs.)
7. Install starter, and tighten the bolts to the specified torque.
Torque: 40 Nm (30 ft. lbs.)
8. Connect transmission harness connectors to transmission, transfer, and right catalytic converter.
9. Connect fuel pipe bracket to transmission side.
For 4X4 (TOD)
For 4X4
For 4X2
10. Install transmission oil cooler pipe to transmission.
Torque: 44 Nm (33 ft. lbs.)
11. Install oil pipe clamp to torque converter housing bracket.
12. Tighten oil pipe clamp bolt at engine mount side.
13. Install right catalytic converter, tighten to the specified torque.
Torque: 67 Nm (49 ft. lbs.)
14. 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.)
15. Install left seat belt tension rod.
16. Install two left side oxygen sensor connectors to the transmission harness.
17. Install front exhaust silencer mounting nuts.
18. Install third crossmember, and tighten the bolts to the specified torque.
Torque: 76 Nm (56 ft. lbs.)
19. Install rear mount nuts, and tighten the bolts to the specified torque.
Torque: 50 Nm (37 ft. lbs.)
20. Remove the jack from the transfer case.
21. Install harness protector.
22. Install the front propeller shaft, and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)
23. Install the rear propeller shaft, and tighten the bolts to the specified torque.
Torque: 63 Nm (46 ft. lbs.)
24. Connect the shift control rod to selector lever assembly.
25. Install the transfer protectors, and tighten the bolts to the specified torque (4X4).
Torque: 37 Nm (27 ft. lbs.)
26. Install the transfer control lever (4X4).
27. Connect the selector lever assembly.
28. Connect the wiring harness connectors to front console.
29. Install the front console.
30. Install the transfer control lever knob (4X4).
31. Connect the battery ground cable.
32. Install the engine hood.