Removal and Installation

Exploded View AT-241:

Removal and Installation

REMOVAL
1. Remove the drain plug and gasket. Drain the fluid.
2. Remove the A/T undercover using power tool.
3. Remove the center exhaust tube and main muffler.
4. Remove the front and rear propeller shafts.

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 the A/T nuts from the A/T crossmember.
6. Position two suitable jacks under the A/T and transfer assembly.
7. Remove the crossmember. Refer to Exploded View AT-241.

WARNING: Support A/T and transfer assembly using two suitable jacks while removing crossmember.

8. Disconnect the electrical connectors from the following:
^ ATP switch
^ Neutral 4LO switch
^ Wait detection switch
^ Transfer motor
^ Transfer control device
^ Transfer terminal cord assembly
9. Disconnect each air breather hose from the following.
^ Actuator
^ Breather tube (transfer)
^ Transfer motor (case connector)
10. Remove the transfer control device from the extension housing.
11. Remove the transfer to A/T and A/T to transfer bolts.

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

12. Remove the transfer assembly.

INSTALLATION
Installation is in the reverse order of removal.





^ Tighten the bolts to specification.
Bolt length: 45 mm (1.77 in)
Transfer bolt torque: 36 Nm (3.7 kg-m, 27 ft-lb)
^ After installation check the transfer fluid level and for fluid leakage.
^ After filling, start the engine and let it run for one minute. Then stop the engine and recheck the transfer fluid.