Removal and Installation

Dismounting and Remounting
Dismounting and remounting of transfer and transmission together as a unit is described in "Manual Transmission Assembly Dismounting and Remounting: Type 1. or "Automatic Transmission (with Transfer) Dismounting and Remounting:", but it is also possible to dismount and remount transfer assembly by itself as described below.

Dismounting





1) In engine room a) Disconnect negative (-) cable from battery. b) Remove distributor assembly. c) Place wood block between engine and dash panel so that it serves as stopper when engine, transmission and transfer unit hangs down as rear mounting member is removed.

CAUTION: Make sure to use wood block to prevent contact which may occur between dash panel and CMP sensor case (for G16 engine model), CMP sensor (for J20 engine model) or intake manifold (for H25 engine model), and fan and shroud.

2) In cabin
a) Remove console box.
b) Remove shift lever of transmission and transfer.





3) On lift
a) Drain transfer oil.
b) Remove rear propeller shaft.
c) Remove front propeller shaft.
d) Disconnect exhaust center pipe.
e) Disconnect speed sensor coupler.
f) Place transmission jack (1) and remove mounting member (2).
g) Lower transmission jack (1) gradually and check to ensure that wood block serves as stopper between engine and dash panel.
h) Remove bolts (4) for gear shift lever case (3).
i) Pull off breather hose.





4) In cabin
a) Remove gear shift lever case and then remove transfer center case bolt (1).
5) On lift





a) Remove transfer mounting (engine rear mounting (2)) by removing bolts (1).
b) Apply transmission jack (3) to transfer (2) to support it.
c) Remove couplers for 4WD/4WD-LOW switches lead.
d) Remove transfer front case bolts (1).





e) With transfer assembly (2) supported with transmission jack (3), slide it rearward and when it is apart from transmission, lower it.

Remounting
For remounting, reverse dismounting procedure described above, noting the followings.
^ Be sure to use specified torque for tightening.
^ Clamp wiring and breather hose securely.
^ Clamp shift lever boot securely.
^ Fill specified gear oil by specified amount.
^ Connect battery and check for function.