Removal and Installation

REMOVAL
1. Remove transmission shift lever, as follows:
a. Remove the four screws and front console box.
b. Remove the four screws and shift lever boot retainer.





c. Cover the shift lever cap with a cloth.
d. Then, pressing down on the shift lever cap, rotate it counterclockwise to remove.
e. Pull out the shift lever.

INSTALLATION NOTE: Apply Multi-Purpose (MP) grease to the tip of the shift lever.





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

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

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





3. Raise vehicle and drain transmission oil.
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 2.2 L (2.3 US quarts).
Torque: 37 N.m (27 ft. lbs.).
4. Remove front and rear propeller shafts.
5. Disconnect speedometer cable.
6. Disconnect back-up light switch and 4wd indicator switch connectors.
7. Remove clutch release cylinder and line. Remove the four bolts, release cylinder and line.
Torque: 12 N.m (108 inch lbs.)
8. Remove front exhaust pipe, as follows:





a. Remove the two nuts, gasket and oxygen sensor.
b. Remove the two bolts, retainer and gasket.
Torque: 48 N.m (35 ft. lbs.).





c. Remove the three bolts and bracket.
Torque: 44 N.m (33 ft. lbs.).
d. Remove the three nuts, front exhaust pipe and two gaskets.
Torque: 62 N.m (46 ft. lbs.).
9. Remove starter, as follows:
a. Disconnect the connector and wire from the starts
b. Remove the two bolts and starter.
Torque: 39 N.m (29 ft. lbs.).





10. Remove stiffener plate (RH and LH) and rear end plate. Remove the eight bolts. stiffener plate Right and Left Hand (RH and LH) and rear end plate.
Torque: 37 N.m (27 ft. lbs.).
11. Remove stabilizer bar.
12. Jack up transmission slightly. Using a transmission jack, support the transmission.
13. Remove crossmember, as follows:
a. Remove the four set bolts of the engine rear mounting.
Torque: 13 N.m (108 inch lbs.).
b. Remove the eight bolts and crossmember.
Torque: 95 N.m (70 ft. lbs.).
14. Remove transmission with transfer, as follows:





a. Remove the six transmission mounting bolts from the engine.
Torque: 72 N.m (53 ft. lbs.).
b. Disconnect the wire harness from the transmission.
c. Pull out the transmission with the transfer down and toward the rear.
15. Remove engine rear mounting. Remove the four bolts and engine rear mounting.
Torque: 65 N.m (48 ft. lbs.).
16. Remove transfer from transmission, as follows:
a. Remove the transfer adaptor rear mounting bolts.
Torque: 37 N.m (27 ft. lbs.).





b. Pull the transfer straight up and remove it from the transmission.

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

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