Removal and Replacement

Dismounting
In cabin
Remove transmission shift control lever and transfer shift control lever knob.

In engine room
1) Disconnect negative (-) cable of battery.





2) Remove breather hose (3) from clamp (2) at the rear end of cylinder head.





3) Remove starting motor fixing bolts (2) and nut (3) and then remove starter (1).





4) Remove transmission fastening bolts (1).

On lift
1) Remove skid plate (if equipped).
2) Drain oil from transmission and transfer.
3) Give match marks (1) on joint flange and propeller shaft as shown in figure. (front and rear)
4) Remove flange bolts (2) of rear propeller shaft universal joint and pull out propeller shaft (3).





5) Remove flange bolts (2) of front propeller shaft universal joint and pull out propeller shaft (3).
6) Remove clutch operating cylinder from transmission. It is not necessary to disconnect clutch hose from operating cylinder.

NOTE: It is not necessary to drain transmission oil when dismounting transmission and transfer for clutch maintenance only. Work without draining transfer oil is possible if front propeller shaft is dismounted together with transmission and transfer.

7) Remove clutch housing lower plate.
8) Disconnect couplers from 4WD switch, back up light switch and speed sensor assembly and release their harness from clamps.





9) Remove nuts (1) from joint with engine.





10) Apply transmission jack (1) and remove engine rear mounting member (2) taking off its bolts.
11) After removing mounting member, move rearward transmission and transfer assemblies placed on jack and then lower them.
12) Remove wiring harness (3) and breather hose (4).





13) Separate gear shift lever case (5) and transfer assembly (2) (or extension case for 2WD model) from transmission assembly (1).

Remounting





For remounting, reverse dismounting procedure.
^ Use specified torques as given below.
Tightening torque
Transmission to engine bolt and nut (a): 85 Nm (8.5 kgf-m, 61.5 ft. lbs.)
Engine rear mounting bolt and nut (b): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
Exhaust center pipe to manifold nut (c): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
Muffler to exhaust center pipe bolt (d): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
Universal joint flange bolt (e): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
^ For tightening torque of transmission stiffener bolt, refer to "Engine Assembly Installation: G16 Engine", "Engine Assembly Removal and Installation: J20 Engine" or "Engine Assembly Removal and Installation: H25 Engine".
^ Set each clamp for wiring, hose and cable securely.
^ Set clamp for shift control lever boots securely.
^ After installing clutch operating cylinder, check clutch pedal free travel.
^ Fill gear oil to transmission and transfer as specified.
^ Connect battery and check function of engine, clutch, transmission and transfer.
^ When installing propeller shaft, align the match marks (1).