Overhaul (Dismounting & Remounting)
Manual Transmission Assembly Dismounting and RemountingDismounting
1) Disconnect negative (-) cable of battery.
2) Remove transmission shift control lever.
3) For transfer (lever-shift type), remove transfer shift control lever.
4) Detach couplers from their bracket and disconnect HO2S lead wires at couplers (1).
5) Remove 3 transmission fastening bolts at engine room with engine harness clamp disconnected from intake connector.
6) Hoist vehicle.
7) Drain oil from transmission.
8) For 4WD vehicle, drain oil from transfer.
9) Remove propeller shaft(s).
10) Remove exhaust No. 1 pipe (1) and No. 2 pipe (2).
11) Remove exhaust manifold stiffeners.
12) Remove starting motor bolts (1).
13) Remove clutch operating cylinder (2) from transmission. It is not necessary to disconnect clutch hose from operating cylinder.
14) Remove clutch housing lower plate.
15) Remove transmission fastening bolt (1) and nuts (2).
16) Disconnect couplers from 4WD switch, back up light switch and speed sensor assembly and release their harness from clamps.
17) Apply transmission jack (1) and remove engine rear mounting member (2) taking off its
18) After removing mounting member, move rearward transmission and transfer assemblies placed on jack and then lower them.
19) Remove breather hose (1).
20) Separate gear shift lever case (2) and transfer assembly (3) (or extension case for 2WD model) from transmission assembly (4).
Remounting
For remounting, reverse dismounting procedure.
^ Slant the rear of the engine down, using support device (1) and install transmission to engine.
^ Use specified torques as given below.
Tightening torque
Transmission to engine bolt and nut a: 85 Nm (8.5 kg-m, 61.5 ft. lbs.)
Engine rear mounting bolt and nut b: 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
Exhaust No. 1 pipe to exhaust No. 2 pipe bolts c: 50 Nm (5.0 kg-m, 36.5 ft. lbs.)
Exhaust No. 2 pipe to muffler bolts: 50 Nm (5.0 kg-m, 36.5 ft. lbs.)
Engine rear mounting bolts d: 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
^ Set each clamp for wiring and hose securely.
^ Set clamp for shift control lever boots securely.
^ After installing clutch operating cylinder, check clutch pedal free travel. Refer to Clutch Operating Cylinder Removal and Installation.
^ Fill gear oil to transmission.
^ Fill gear oil to transfer.
^ Connect battery and check function of engine, clutch, transmission and transfer.
^ Install propeller shaft(s).