Replacement

WARNING: Where the use of a transmission hoist is necessary, it is absolutely essential to follow the manufacturer's instructions to ensure safe and effective use of equipment.

REMOVAL
1. Install vehicle on a ramp [hoist].
2. Disconnect battery earth lead.
3. Remove center console.
- Refer to Body and Frame
4. Remove sound insulation from top of transmission tunnel.
5. Remove bolt and remove upper gear lever.
6. Remove screws securing gear selector lever and high/low selector lever draft excluders.
7. Remove draft excluder clamp rings.





8. Remove handbrake cable clevis pin clip and clevis pin.
9. Remove "C" clip and cable adjuster.
10. Select low range to prevent gear lever fouling tunnel when removing gearbox.
11. Remove bolt securing gearbox breather pipe clip to cylinder block.
12. Remove bolts securing fan cowl to radiator.
13. Release fan cowl from radiator and lay over-fan blades.
14. Raise ramp [hoist].
15. Drain oil from main gearbox and transfer gearbox.
- Tighten drain bolt to 30 Nm.
16. Remove exhaust front pipe(s), refer to Exhaust System.
17. Release intermediate exhaust pipe(s) from mountings and tie aside.
18. Remove bolts securing clutch slave cylinder.
19. Release slave cylinder from clutch housing and collect spacer.
20. Mark propeller shaft drive flange relationships for reassembly.
21. Disconnect front and rear propeller shafts from transfer gearbox.
- Tie shafts aside.
22. Remove clamp and disconnect speedometer cable from transfer gearbox.
23. Release handbrake cable from transmission tunnel.
24. Temporarily support transmission in a way which enables the crossmember to be removed and a hoist cradle to be installed.
25. Remove nuts and bolts securing transmission cross-member to chassis.
26. Remove nuts and bolts securing cross-member mountings to transmission.
27. Remove cross-member.





28. Manufacture an adapter plate to dimensions shown in the illustration above and attach it to a transmission hoist.
- To achieve balance of the transmission unit when mounted to hoist, it is essential that point A, is situated over lifting hoist ram.
- Drill holes B to suit hoist table.
- Secure the transmission unit cradle at point C using the lower bolts retaining transfer gearbox rear cover.
- Raise hoist just enough to take weight of transmission.
29. Lower hoist sufficiently to allow transfer gearbox selector lever to clear transmission tunnel aperture.
30. Disconnect differential lock switch connectors.
31. Disconnect reverse lamp switch connectors.
32. Remove clips securing gearbox breather pipes to harness.
33. Support engine under oil pan with a jack.

CAUTION: Use a wooden block to protect oil pan.

34. Remove bell housing nuts.
35. Withdraw transmission while ensuring all connections to engine and chassis are released.
36. Remove transmission assembly from hoist cradle and position safely on a bench.





37. Remove breather pipes.
- Discard pipe union sealing washers.
38. Remove "Nyloc" nut, and remove bolt, securing lever to high/low shaft.
39. Collect spacer washer.
40. Remove 2 clips and remove differential lock lever link.
41. Remove lower locknut from high/low operating rod.
42. Place a sling round transfer box and attach to hoist.

REMOVE TRANSFER GEARBOX FROM MAIN GEARBOX
43. Remove nut and 5 bolts securing transfer gearbox to extension housing.
44. Withdraw transfer gearbox.

ASSEMBLING TRANSFER GEARBOX TO MAIN GEARBOX
45. Clean extension housing and transfer gearbox mating faces.
46. Ensuring loose upper dowel is installed, hoist transfer gearbox into position.
47. Install and tighten nut and bolts to 34 Nm.
48. Connect high/low operating rod, install and tighten locknut.
49. Install link to differential lock lever and secure with 2 clips
50. Align lever to high/low shaft, position washer, install bolt and new Nyloc nut.
- Tighten to 2 Nm.
51. Position breather pipes, secure pipe unions using new sealing washers.
- Tighten unions to 15 Nm.

INSTALLING TRANSFER GEARBOX AND MAIN GEARBOX ASSEMBLY TO ENGINE
52. Position transmission assembly to hoist cradle.
53. Clean bell housing and engine mating faces.
54. Temporarily install gear lever and select any gear in main gearbox to facilitate entry of gearbox input shaft.
55. Position and raise hoist, and install transmission to engine while keeping wires and pipes clear to prevent trapping.
56. Install and tighten nuts securing transmission to engine.
57. Connect reverse lamp switch connectors and differential lock switch connectors.
58. Secure breather pipes to harness with clips.
59. Position temporary support.
60. Remove 2 bolts securing lifting cradle to transmission and remove hoist.
- Apply Loctite 290 to bolts and install bolts.
61. Position cross-member, loosely install nuts and bolts securing cross-member mountings to transmission.
62. Raise transmission, align cross-member and loosely install nuts and bolts securing cross-member to chassis.
63. Tighten all securing nuts and bolts.
- Remove supporting jack from under oil pan.
64. Remove temporary support.
65. Install handbrake cable through transmission tunnel and secure gaiter.
66. Connect speedometer cable to transfer gearbox.
67. Line up marks and connect front and rear propeller shafts.
68. Clean spacer, clutch slave cylinder and gearbox mating faces.
69. Position spacer and slave cylinder, install bolts.
- Tighten to 25 Nm.
70. Untie intermediate exhaust pipe(s) and install exhaust front pipe(s).
71. Refill main gearbox and transfer gearbox with oil.
- Fill Transfer Box with 2.30 liters (4.90 US pints) of API GL5 or MIL-L-2105 90W EP gear oil.
- Fill manual gearbox with 2.67 liters (5.70 US pints) of Dexron IID ATF.
72. Lower ramp [hoist].
73. Install fan cowl, install and tighten bolts.
74. Align breather pipe clip to cylinder block, install an-d tighten bolts.
75. Install handbrake cable adjuster and secure with "C" clip.
76. Align cable trunnion to handbrake lever, install clevis pin and secure with clip.
77. Check handbrake adjustment, refer to Brakes and Traction Control.
78. Install upper gear lever, install and tighten bolt.
79. Install gear selector lever and high/low selector lever draft excluders.
80. Position draft excluder clamp rings, install and tighten screws.
81. Install sound insulation.
82. Install center console.
83. Connect battery earth lead.