Removal and Installation

REMOVAL





1. Remove transmission shift lever.
a. Remove the front console box.
b. Remove the 4 screws, shift lever boot and retainer.
c. Cover the shift lever cap with a cloth.
d. Pressing down on the shift lever cap and rotate it counterclockwise to remove.
e. Pull out the shift lever.

INSTALLATION HINT: Apply UP grease to the tip of the shift lever.





2. Remove transfer shift lever.
Using pliers, remove the snap ring and pull out the shift lever.

HINT: Shift the transfer shift lever to the "H4" position.

INSTALLATION HINT: Apply MP grease to the tip of the shift lever.





3. Raise vehicle and drain transmission oil.
Oil grade: API GLEN or GL-5
Viscosity: SAE 75W-90
Capacity: 2.2 liters (2.3 US Qts)
Torque: 37 N.m (27 ft. lbs.)
4. Remove No.1 and No.2 engine under covers.
5. Remove front propeller shaft.
6. Remove rear propeller shaft.
7. Disconnect L4 position switch, 4wd position switch, vehicle speed sensor and back-up light switch connectors.
8. Remove clutch release cylinder and line Remove the 4 bolts and release cylinder and line.
Torque: 12 N.m (9 ft. lbs.)
9. Remove front exhaust pipe.





a. Disconnect the ring, remove the 2 bolts and support bracket.
Torque: 19 N.m (14 ft. lbs.)
b. Remove the 2 bolts, bracket and gasket.
Torque: 48 N.m (35 ft. lbs.)





c. Remove the 2 nuts, oxygen sensor and gasket.
d. Remove the 3 bolts and bracket.
Torque: 44 N.m (33 ft. lbs.)
e. Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 N.m (46 ft. lbs.)





10. Remove rear end plate.
Remove the 4 bolts and rear end plate.
Torque: 18 N.m (13 ft. lbs.)





11. Remove crossmember.
a. Support the transmission rear side.
b. Remove the 4 set bolts of the engine rear mounting.
Torque: 18 N.m (13 ft. lbs.)
c. Remove the 4 bolts, nuts and crossmember.
Torque: 65 N.m (48 ft. lbs.)
12. Remove engine rear mounting.
Remove the 4 bolts and engine rear mounting from the transmission.
Torque: 65 N.m (48 ft. lbs.)
13. Jack up transmission slightly.
Using a transmission jack, support the transmission.





14. Remove starter.
a. Disconnect the connector and wire from the starter.
b. Remove the 2 bolts and starter.
Torque: 39 N.m (29 ft. lbs.)
15. Remove transmission with transfer.
a. Disconnect the wire harness from the transmission.
b. Remove the 6 transmission mounting bolts from the engine.
Torque: 72 N.m (53 ft. lbs.)
c. Pull out the transmission with the transfer down and toward the rear.





16. Remove transfer from transmission.
a. Disconnect the breather hose and remove the 8 transfer adaptor rear mounting bolts.
Torque: 24 N.m (17 ft. lbs.)
b. Pull the transfer straight up and remove it from the transmission.

HINT: Take care not to damage the transfer adaptor oil seal with the transfer input gear spline.

INSTALLATION HINT: Apply MP grease to the lip of the transfer adaptor oil seal.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, do the road test.