Removal and Installation

Removal and Installation
REMOVAL
1. Switch 4WD shift switch to 2WD and set transfer assembly to 2WD.
2. Remove the transmission undercover using power tool.
3. Remove the center exhaust tube and main muffler.
4. Remove the front and rear propeller shafts. Refer to "Removal and Installation" (front) and "Removal and Installation" (rear).

CAUTION: Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft.

NOTE: Insert a plug into the rear oil seal after removing the rear propeller shaft.

5. Remove transmission bolts. Refer to "COMPONENTS" (M/T) or "COMPONENTS" (A/T).
6. Position two suitable jacks under the transmission and transfer assembly.
7. Remove the transmission crossmember. Refer to "COMPONENTS" (M/T) or "COMPONENTS" (A/T).

WARNING: Support transmission and transfer assembly using two suitable jacks while removing transmission crossmember.

8. Disconnect the breather hoses from the transfer rear case and transfer control device.
9. Disconnect the electrical connectors from the following:
^ ATP switch
^ 4LO switch
^ Wait detection switch
^ Transfer control device





10. Remove the transfer to transmission and transmission to transfer bolts.

WARNING: Support transfer assembly with suitable jack while removing it.

11. Remove the transfer assembly.

CAUTION: Do not damage transmission rear oil seal.

INSTALLATION





Installation is in the reverse order of removal.
^ Tighten the bolts to specification.
Tightening torque: 36 Nm (3.7 kg-m, 26 ft. lbs.)
^ Fill the transfer with new fluid. Refer to "FILLING".
^ Check the transfer fluid. Refer to "FLUID LEAKAGE AND FLUID LEVEL".
^ Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to "FLUID LEAKAGE AND FLUID LEVEL".
^ After the installation, check the 4WD shift indicator pattern. If NG, adjust the position between the transfer assembly and transfer control unit. Refer to "Precautions for Transfer Assembly and Transfer Control Unit Replacement".