Shifter M/T: Service and Repair

REMOVAL
1. Raise vehicle on four post lift.
2. Disconnect battery negative lead.
3. Remove center console.





4. Remove 6 nuts securing gaiter ring. Remove ring and gaiter.





5. Remove 2 bolts securing gear lever. Remove lever.





6. Remove Handbrake cable clevis pin.
7. Raise lift.
8. Support gearbox using transmission jack.
9. Remove exhaust front pipe.
10. Diesel Vehicles. Remove chassis cross member.
11. Release hand brake cable from grommet in tunnel. Install grommet to tunnel.





12. Remove 4 bolts securing propeller shaft guard. Remove guard.





13. Disconnect 2 Lucars from transfer box oil temperature sensor.
14. Disconnect multiplugs from High/Low motor and output shaft speed sensor.
15. Release harness from 2 clips on transfer gearbox brackets.
16. Lower gearbox for access.

CAUTION: Ensure engine does not foul bulkhead.





17. Disconnect neutral switch multiplug.
18. Remove 4 bolts securing remote housing to gearbox. Position harness bracket aside.
19. Remove selector remote housing from 2 location dowels.

INSTALLATION
20. Ensure all mating faces are clean.
21. Apply a uniform bead of Hylogrip 2000 to sealing face of remote housing as shown.
22. Position remote housing. Engage remote spigot into selector yoke.
23. Engage housing to location dowels. Align harness bracket.
24. Secure remote housing with bolts. Tighten to 25 Nm (18 ft. lbs.).
25. Connect neutral switch multiplug.
26. Connect multiplugs to High/Low motor and output shaft speed sensor.
27. Connect Lucars to transfer box fluid temperature sensor.
28. Secure harness in clips.
29. Position propeller shaft guard. Secure with bolts.
30. Route hand brake cable through grommet in transmission tunnel.
31. Install exhaust front pipe.
32. Diesel Vehicles. Install chassis cross member.
33. Remove jack. Lower lift.
34. Connect Handbrake cable to lever. Secure with clevis pin and clip.
35. Install seal around gearbox remote housing to transmission tunnel aperture.
36. Position gear lever. Secure with bolts. Tighten to 25 Nm (18 ft. lbs.).
37. Install gaiter and ring. Secure with nuts.
38. Install center console.
39. Reconnect battery negative lead.