Transmission Case

REMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Prepare the transmission for overhaul.
3. Remove the oil pipe, neutral position switch, back-up light switch and harness.
4. Remove the extension case.
5. Remove the transfer driven gear.
6. Remove the center differential.





7. Remove the oil pump.
8. Remove the shim and spacer of driven gear assembly.





9. Remove the snap ring.





10. Remove the pilot bolt.





11. Remove the holder reverse bolt.





12. Remove the transmission case.

NOTE: If the oil guide catches on shift fork, the transmission case may be difficult to be removed. Move the oil guide right and left to remove. Do not pull the transmission case by force.

13. Completely remove the remaining liquid gasket on transmission case and adapter plate.

INSTALLATION





1. Make sure that each shifter fork and interlock block is shifted to neutral position. If not, shift to neutral position.





2. Apply liquid gasket to the adapter plate.
Liquid gasket: THREE BOND 1215 (Part No. 004403007)
3. Install the transmission case.





4. Make sure the interlock block and reverse interlock block are aligned in neutral position by inspecting through the pilot bolt installation hole. If not aligned, remove the transmission case, then shift each shifter fork and interlock block to neutral position.
5. Using a new gasket, install the pilot bolts temporarily.
6. Tighten the transmission case with bolts and nuts.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
7. Tighten the pilot bolts.
Tightening torque: 34 Nm (3.5 kgf-cm, 25.1 ft. lbs.)
8. Tighten the holder reverse bolt.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)





9. Install the snap ring, washer and collar of driven gear assembly.
10. Install the oil pump.
11. Install the center differential.
12. Install the transfer driven gear.
13. Install the extension case.
14. Install the oil pipe, neutral position switch, back-up light switch and harness.
15. Install the manual transmission assembly to vehicle.

DISASSEMBLY





1. Remove the oil pipe and oil guide.





2. Remove the bolt, and then remove the O-ring, relief spring and relief valve.





3. Remove the bolt, and then remove the O-ring, valve spring and ball.





4. Remove the harness bracket.





5. Remove the oil pan.
6. Completely remove the remaining liquid gasket on transmission case and oil pan.





7. Remove the oil pan magnet, and then remove the oil strainer.

ASSEMBLY





1. Install the oil strainer and magnet.
Tightening torque: 10 Nm (1.0 kgf-cm, 7.4 ft. lbs.)





2. Apply liquid gasket to the oil pan.
Liquid gasket: THREE BOND 1215 (Part No. 004403007)





3. Install the oil pan.
Tightening torque: 6.4 Nm (0.65 kgf-cm, 4.7 ft. lbs.)
4. Install the relief valve, relief valve spring and new O-ring.





5. Install the ball, valve spring and new O-ring.
Tightening torque:
T1: 13 Nm (1.3 kgf-cm, 9.6 ft. lbs.)
T2: 16 Nm (1.6 kgf-cm, 11.8 ft. lbs.)

INSPECTION
1. Completely remove with shop cloth if sludge is adhered to the oil pan magnet.
2. Make sure there is no clog on the oil strainer. If clogged, remove clog or replace the oil strainer.
3. Make sure there is no damage on each parts. Replace damaged parts with new parts.