Removal/Installation
Transmission Lift Adapter, Transfer Case:
NOTE:
^ Removal, refer to steps 1 through 50
^ Installation, refer to steps 51 through 95
^ The transfer gearbox should be removed from underneath the vehicle, using a hydraulic hoist and adaptor plate LRT-99-010 as shown in the illustration.
WARNING: Where use of a transmission hoist is necessary, it is absolutely essential to follow the manufacturers' instructions to ensure safe and effective use of the equipment.
REMOVAL
1. Position vehicle on a ramp [hoist].
2. Select LOW range gear and leave vehicle in neutral.
3. Disconnect battery negative lead.
4. Remove center console.
5. Remove carpet from transmission tunnel.
6. Remove high-low selector housing cover from transmission tunnel.
7. Remove 3 trim studs securing handbrake lever boot.
8. Release handbrake lever boot for access to handbrake cable linkage.
9. Remove split [cotter] pin and clevis pin securing handbrake cable to lever.
10. Remove 2 screws securing fan cowl to upper retaining brackets.
11. Release 2 clips securing upper fan cowl.
12. Remove upper fan cowl.
13. Raise ramp [hoist].
14. Drain transfer gearbox oil.
15. Remove exhaust front pipe.
16. Remove 2 nuts securing intermediate pipe to tail pipe.
17. Release intermediate pipe from tail pipe and remove from mounting.
18. Remove 8 bolts securing chassis crossmember.
19. With assistance and using a body jack between chassis rails, jack chassis sufficiently to enable removal of crossmember.
20. Remove crossmember.
21. Remove body jack.
22. Using a center punch, mark relationship between front propeller shaft and transfer box drive flanges and rear propeller shaft and brake drum drive flanges.
23. Remove 4 nuts securing front propeller shaft to transfer box flange. Release propeller shaft from flange and tie aside.
24. Remove 4 nuts securing rear propeller shaft to brake drum flange. Release propeller shaft from flange and tie aside.
25. Remove nut securing tie bar to gear box and 2 bolts securing tie bar to transfer box.
26. Remove tie bar.
27. Remove bolt securing selector outer cable clamp to transfer gearbox LH mounting.
28. Remove nut securing oxygen sensor multiplug bracket to transfer gearbox earth bolt and collect bracket.
29. Remove nut securing earth strap to transfer gearbox and release strap.
30. Release handbrake outer cable from body.
Ground Lead At Transfere Box:
31. Remove bolt securing ground lead to RH side of transfer gearbox.
32. Remove bolt securing handbrake cable heat shield. Remove heat shield.
33. Position adaptor plate, LRT-99-010, and secure to transmission hoist with 4 bolts.
34. Remove 4 central bolts from transfer gearbox bottom cover, move hoist into position and secure adaptor plate to transfer box.
35. Adjust hoist to take weight of transfer gearbox.
36. Remove 2 nuts and bolts securing heat shield to transfer gearbox LH mounting bracket. Remove heat shield.
37. Remove 3 nuts and bolts securing LH gearbox mounting bracket to chassis.
38. Remove nut securing transfer gearbox RH mounting to mounting rubber.
39. Remove 3 nuts and bolts securing transfer gearbox mounting bracket to chassis. Remove transfer box RH mounting bracket and collect rubber mounting heat shield.
40. Lower transmission sufficiently to gain access to harness connectors and transfer box breather pipe connection.
41. Remove banjo bolt from transfer box breather pipe and collect 2 sealing. Discard sealing washers.
42. Remove retaining clip and disconnect high/low lever from operating rod.
43. Remove 2 clips at lower end of pivot arm and disconnect differential lock lever link.
44. Disconnect the following multiplugs/connectors from transfer box: Speed transducer Parking solenoid Neutral detection switch Differential lock Temperature sensor switch
45. Remove 2 clips securing harness to transfer box.
46. Position a jack to support main gearbox.
CAUTION: Use a block of wood or hard rubber pad to protect gearbox.
47. Remove nut and 4 bolts securing transfer box to main gearbox extension case.
48. Install 3 guide studs, LRT-41-009, through transfer box bolt holes to support it during removal.
49. Lower hoist and withdraw transfer box from main gearbox.
50. Remove transfer box.
INSTALLATION
51. Ensure joint faces of transfer box and main gearbox are clean and guide studs, LRT-41-009 are installed to extension case.
52. Lubricate oil seal in joint face of transfer box.
53. Secure transfer box to adaptor plate on lifting hoist and raise hoist until transfer box can be located over guide studs.
54. Remove guide studs, and secure transfer box to main gearbox extension case. Tighten fixings to 45 Nm (33 ft. lbs.).
55. Connect multiplugs/connectors to transfer box.
56. Position breather pipe to transfer box, install new sealing washers and tighten banjo bolt to 15 Nm (11 ft. lbs.).
57. Install link to differential lock lever and pivot arm and secure with retaining clips.
58. Connect high/low lever to operating rod and secure with retaining clip.
59. Raise hoist and remove jack supporting main gearbox.
60. Position RH mounting rubber heat shield and mounting bracket and secure loosely with retaining nut.
61. Align RH mounting bracket to chassis and secure with nuts and bolts.
62. Tighten nut securing RH mounting.
63. Align LH mounting bracket to chassis and secure with nuts and bolts.
NOTE: Position ground lead to mounting bolt.
64. Remove 4 bolts securing hoist adaptor plate to transfer box bottom cover.
65. Lower hoist and move aside.
66. Clean threads of the 4 bolts, coat with Loctite 290, and install to transfer box bottom cover. Tighten to 25 Nm (18 ft. lbs.).
67. Position handbrake cable heat shield and tighten bolt.
68. Position ground lead to RH side of transfer box and tighten bolt.
69. Feed handbrake cable through body.
NOTE: Apply a soap solution to aid installation of cable.
70. Position ground strap to transfer box stud and tighten nut.
71. Install heated oxygen sensor multiplug bracket to stud and tighten nut.
72. Position selector outer cable clamp to transfer box LH mounting and tighten bolt.
73. Install tie bar and tighten bolts and nut.
74. Clean rear propeller shaft and brake drum flange mating faces.
75. Release propeller shaft, align flange markings and connect to studs.
76. Install nuts securing propeller shaft and tighten to 47 Nm (33 ft. lbs.).
77. Clean front propeller shaft and transfer box flange mating faces.
78. Release propeller shaft, align flange markings and connect to studs.
79. Install nuts securing propeller shaft and tighten to 47 Nm (33 ft. lbs.).
80. With assistance and using a body jack between chassis rails, jack chassis sufficiently to enable installation of crossmember.
81. Install crossmember and tighten bolts.
82. Clean intermediate and tail pipe flanges.
83. Install intermediate pipe to mounting rubber, connect to tail pipe and tighten nuts.
84. Install exhaust front pipe.
85. Refill transfer box with recommended oil. Lower vehicle ramp.
87. Install upper fan cowl and secure clips.
88. Align fan cowl to upper retaining brackets and tighten screws.
89. Align handbrake cable to lever, install clevis pin and secure with new split [cotter] pin.
90. Position handbrake lever cover and secure with trim studs.
91. Install high-low selector housing cover to transmission tunnel.
92. Install carpet to transmission tunnel.
93. Install center console.
94. Reconnect battery negative lead.
95. Check park brake operation and adjust if necessary.