Removal and Installation

REMOVAL
1. Remove transmission shift lever.
a. Remove the 4 screws and front console box.
b. Remove the 4 screws and 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 MP 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" (w/o One Touch 2-4 selector system) or "H2" (w/ One Touch 2-4 selector system) position.

INSTALLATION HINT: 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 liters (2.3 US Qts)
Torque: 37 N.m (27 ft. lbs.)
4. Remove front and rear propeller shafts.
5. Disconnect speedometer cable and back-up light switch connector.
6. Standard Cab: Disconnect 4WD-position switch connector.
7. extra cab: Disconnect L4 position switch connector.
8. Remove clutch release cylinder remove the 2 bolts and release cylinder.
Torque: 12 N.m (108 inch lbs.)





9. Remove front exhaust pipe.
a. Remove the 2 nuts, gasket, oxygen sensor and insulator.
b. Remove the 2 bolts, nuts and gasket.
Torque: 48 N.m (35 ft. lbs.)





c. Remove the 3 bolts and bracket.
Torque: 44 N.m (33 ft. lbs.)
d. Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 N.m (46 ft. lbs.)
10. 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.)
11. Remove rear end plate.
Remove the 4 bolts and rear end plate.
Torque: 18 N.m (13 ft. lbs.)





12. 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. Disconnect the O-ring and remove the 4 bolts, nuts and crossmember.
Torque: 65 N.m (48 ft. lbs.)
13. Remove engine rear mounting.
Remove the 4 bolts and engine rear mounting.
Torque: 65 N.m (48 ft. lbs.)
14. jack up transmission slightly.
Using a transmission jack, support the transmission.





15. Remove transmission.
a. Remove the 6 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.





16. Remove transfer from transmission.
a. Remove the 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 adaptor rear oil seal with the transfer input gear spline.

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

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, do the road test.