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.

HINT:
At the time of installation, please refer to the following item.
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:
At the time of installation, please refer to the following items.
Shift the transfer shift lever to the "H4" position.
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: 2.5 liters (2.6 US qts, 2.2 Imp. qts)
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

4. REMOVE NO.1 AND NO.2 ENGINE UNDER COVERS
5. REMOVE FRONT AND REAR PROPELLER SHAFTS
6. DISCONNECT VEHICLE SPEED SENSOR, BACK-UP LIGHT SWITCH AND 4WD POSITION SWITCH CONNECTORS
7. w/ABS or / and Diff. Lock: DISCONNECT L4 130SITION SWITCH CONNECTOR
8. DISCONNECT CLUTCH RELEASE CYLINDER
Remove the 2 bolts and disconnect the release cylinder.

Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

9. REMOVE FRONT EXHAUST PIPE





a. Disconnect the ring, and remove the 2 bolts and support bracket.

Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)

b. Remove the 2 bolts, bracket and gasket.

Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





c. Remove the 2 nuts, oxygen sensor and gasket.
d. Remove the 2 set bolts of the front exhaust pipe bracket.

Torque:
Bolt A: 71 Nm (720 kgf-cm, 52 ft. lbs.)
Bolt B: 72 Nm (730 kgf-cm, 53 ft. lbs.)

e. Remove the 3 nuts, front exhaust pipe and 2 gaskets.

Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)





10. REMOVE REAR END PLATE
Remove the 4 bolts, 2 nuts and rear end plate.

Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)





11. REMOVE CROSSMEMBER
a. Support the transmission rear side.
b. Remove the 4 set bolts of the engine rear mounting.

Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

c. Remove the 4 bolts, nuts and crossmember.

Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)

12. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the transmission.

Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)

13. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.





14. REMOVE STARTER
a. Remove the set bolt of the starter on the lower side with the clutch line bracket.

Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

b. Disconnect the connector and wire, and remove the set bolt of the starter on the upper side and starter.

Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

15. REMOVE TRANS164ISSION WITH TRANSFER
a. Disconnect the wire harness from the transmission.
b. Remove the 3 transmission mounting bolts from the engine.

Torque: 72 Nm (730 kgf-cm, 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 Nm (240 kgf-cm, 17 ft. lbs.)

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

HINT:
At the time of installation, please refer to the following items.
Take care not to damage the transfer adaptor oil seal with the transfer input gear spline.
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.