Transmission Case

Transmission Case

REMOVAL
1) Remove the manual transmission assembly from the 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 driven gear assembly shim and spacer.





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 is caught between the shift fork, it may be difficult to remove the transmission case. Move the oil guide and oil pipe, then remove. Do not pull on the transmission case with excessive force.





13) Remove any remaining liquid gasket from the transmission case and adapter plate.

INSTALLATION
1) Check that the shifter fork and the interlock block are both shifted into the neutral position. If they are not, shift into the neutral position.





2) Apply liquid gasket to the adapter plate.





3) Install the transmission case.
4) By inspecting from the pilot bolt attachment hole, check that the interlock block and the reverse interlock block are in the neutral position. If not in the neutral position, remove the transmission case, and shift the shifter fork and interlock block to the neutral position.





5) Temporarily attach the gasket and pilot bolt.

NOTE: Use a new gasket.

6) Affix the transmission case with the bolts and nuts.

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
7) Tighten the pilot bolt.

Tightening torque:
34 Nm (3.5 kgf-m, 25.1 ft-lb)
8) Tighten the holder reverse bolt.

Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
9) Install the snap ring, washer and collar of the 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 the vehicle.

DISASSEMBLY
1) Remove the oil pipe and oil guide.





2) Remove the bolt assembly seal, relief spring and relief valve.





3) Remove the bolt assembly seal, valve spring and ball.





4) Remove the harness bracket.





5) Remove the oil pan.





6) Remove any remaining liquid gasket from the transmission case and oil pan.
7) Remove the oil pan magnet, and remove the oil strainer.





ASSEMBLY
1) Install the oil strainer and magnet.





2) Apply liquid gasket to the oil pan.





3) Install the oil pan.





4) Install the relief valve, relief valve spring and a new bolt assembly seal.
5) Install the ball, valve spring and a new bolt assembly seal.





INSPECTION
1) If there is sludge on the oil pan magnet, use a waste cloth to wipe it off completely.
2) Inspect that the oil strainer is not clogged. If it is clogged, clean or replace the oil strainer.
3) Check that there is no damage on any parts. Replace damaged parts with new parts.