Removal and Installation
REMOVAL
1. Remove ATF level gauge.
2. Remove engine under cover.
3. Disconnect throttle cable.
a. Loosen the nut and disconnect the cable.
b. Separate the throttle cable from the clamp.
4. Remove No.1 fan shroud.
Remove the 4 bolts and No.1 fan shroud.
5. Remove transmission shift lever assembly and transfer shift lever.
a. Remove the 2 bolts, 4 screws and rear console box.
b. w/ One Touch 2-4 selector:
Remove the 3 screws and front console box with the transfer shift lever knob.
w/o One Touch 2-4 selector:
Remove the 2 screws and front console box with the transfer shift lever knob.
c. Disconnect the connectors.
d. Remove the nut and washer, and disconnect the shift control rod.
e. Disconnect the 1 connector and remove the 8 screws and transmission shift lever assembly.
f. Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer.
INSTALLATION HINT: Apply MP grease to the transfer shift lever.
6. Remove oil filler pipe.
Remove the bolt and oil filler pipe with the O-ring.
INSTALLATION HINT: Replace the used O-ring with a new one.
7. Remove front and rear propeller shaft.
8. Remove exhaust pipe.
INSTALLATION HINT: Replace the used gasket and nut with new gaskets and nuts.
9. Disconnect speedometer cable.
10. Disconnect No.2 vehicle speed sensor connector.
11. Disconnect solenoid connector.
12. Disconnect transfer neutral position switch connector.
13. Disconnect transfer L4 position switch connector.
14. Disconnect 4WD-position switch connector.
15. Disconnect oil cooler pipe.
a. Remove the 3 bolts and clamps.
b. Loosen the 2 union nuts and disconnect the 2 oil cooler pipes.
16. Disconnect ATF temperature sensor connector.
17. Disconnect park/neutral position switch connector.
18. Remove starter.
a. Remove the nut and disconnect the connector and terminal.
b. Remove the 2 bolts.and starter.
Torque: 39 N.m (29 ft. lbs.)
19. Remove 4 stabilizer bar bracket mounting bolts.)
20. Remove torque converter clutch mounting bolt.
a. Remove the 4 bolts and flywheel housing under cover.
Torque: 18 N.m (13 ft. lbs.)
b. Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley bolt by a wrench.
Torque: 41 N.m (30 ft. lbs.)
INSTALLATION HINT: First install green colored bolt and then 5 other bolts.
21. Remove front differential rear mounting cushion.
a. Using a hexagon wrench (12 mm), remove the nut.
Torque: 87 N.m (64 ft. lbs.)
b. Lift up the front differential with a support stand.
NOTICE: Be careful not to touch the torque converter clutch housing and front differential companion flange.
c. Remove the 2 rear mounting cushion mounting bolts.
Torque: 108 N.m (80 ft. lbs.)
22. Remove crossmember.
a. Support the transmission rear side with a support stand.
b. Remove the 4 engine rear mounting bolts.
Torque: 19 N.m (14 ft. lbs.)
c. Remove the 4 nuts, bolts and crossmember.
Torque: 65 N.m (48 ft. lbs.)
d. Support the transmission with a transmission jack.
23. Remove transmission.
a. Lower the transmission rear side.
b. Separate the wire harness from the transmission.
c. Remove the 6 bolts and transmission.
Torque: 71 N.m (53 ft. lbs.)
TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION
1. Inspect one-way clutch.
a. Install Special Service Tool (SST) 09350-30020 (09351-32010) in the inner race of one-way clutch.
b. Install SST 09350-30020 (09351-32010) so that it fits in the notch of the converter hub and outer race of the one-way clutch.
c. With the torque converter clutch standing on its side, the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace the converter If the clutch still fails the test.
2. Measure drive plate runout and inspect ring gear.
a. Set up a dial indicator and measure the drive plate runout.
b. Check the damage of the ring gear.
Maximum Runout: 0.20 mm (0.0079 inch)
If runout is not within specification or ring gear is damaged, replace the drive plate.
If installing a new drive plate, note the operation of spacers and torque the bolts.
Torque: 83 N.m (61 ft. lbs.)
3. Measure torque converter clutch sleeve runout.
a. Temporarily mount the torque converter clutch to the drive plate.
b. Set up a dial indicator and measure the torque converter clutch sleeve runout.
Maximum Runout: 0.30 mm (0.0118 inch)
If runout is not within specification, try to correct by reorienting the installation of the converter clutch.
HINT: Mark the position of the converter clutch to ensure correct installation.
INSTALLATION
Installation is in the reverse order of removal.
1. Torque Converter Clutch to Transmission Installation
a. Using calipers and a straight edge, measure from the installed surface of the transmission housing. Correct distance:
More Than 17.95 mm (0.7067 inch)
b. If the distance is less than the standard, check for an improper installation.
HINT:
^ After installation, adjust the shift lever position and throttle cable.
^ Fill and check fluid level.