Removal and Replacement
Manual Transmission Assembly Dismounting and RemountingDismounting
1) Disconnect negative (-) cable of battery.
2) Remove transmission shift control lever referring to Transmission Shift Control Lever Removal and Installation.
3) Detach engine harness clamps and ground wire harness from transmission front case.
4) Remove starting motor fastening bolts (2), transmission fastening bolts (1) and fastening nuts (3).
5) Disconnect clutch fluid joint from pipe of clutch operating cylinder assembly referring to Clutch Operating Cylinder Assembly Removal and Installation.
6) Hoist vehicle.
7) Drain oil from transmission and transfer or extension case.
8) Remove propeller shafts referring to Propeller Shaft Removal and Installation.
9) Remove exhaust No.2 pipe.
10) Remove engine undercover.
11) Remove clutch housing lower plates (1).
12) Remove transmission fastening nut (2) and bolts (3).
13) Disconnect the following couplers and release their harness from clamps.
^ Back up light switch
^ Transfer shift actuator (if equipped)
^ 4L/N switch (if equipped)
^ Center differential lock switch (if equipped)
14) Apply transmission jack (1) and remove engine rear mounting member (2) taking off its bolts.
15) After removing mounting member, move rearward transmission and transfer or extension case assemblies placed on jack and then lower them.
16) Separate gear shift control arm assembly (2) and transfer assembly (3) or extension case from transmission assembly (1).
Remounting
For remounting, reverse dismounting procedure.
^ Apply grease to input shaft.
"A": Grease 99000-25210 (SUZUKI Super Grease I)
^ 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 lbf-ft)
Engine rear mounting member bolt (b): 55 Nm (5.5 kg-m, 40.0 lbf-ft)
Clutch housing lower plate bolt (c): 11 Nm (1.1 kg-m, 8.0 lbf-ft)
Engine rear mounting No.2 bolt (d): 55 Nm (5.5 kg-m, 40.0 lbf-ft)
^ Set each clamp for wiring and hose securely.
^ Install shift control lever referring to Transmission Shift Control Lever Removal and Installation.
^ Connect clutch fluid joint to pipe of clutch operating cylinder assembly referring to Clutch Operating Cylinder Assembly Removal and Installation.
^ Install exhaust No.2 pipe referring to Exhaust System Components.
^ Fill gear oil to transmission referring to Manual Transmission Oil Change.
^ Fill gear oil to transfer or extension case referring to Transfer Oil Change:Motor-Shift Type (Transfer with Shift Actuator) or Extension Case Oil Change.
^ Install propeller shafts referring to Propeller Shaft Removal and Installation.
^ Connect battery and check function of engine, clutch, transmission and transfer.
