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 item.
- Apply MP grease to the tip of the shift lever.

2. REMOVE TRANSFER 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, 1.9 Imp. qts)
Torque: 37 Nm (380 kgf-cm, 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. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE
Remove the 4 bolts and release cylinder and line.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
9. REMOVE FRONT EXHAUST PIPE





a) Disconnect the ring, 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 3 bolts and bracket.
Torque: 44 Nm (450 kgf-cm, 33 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 and rear end plate.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





11. REMOVE CROSSMEMBER
a) Support the rear side of the transmission.
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) Disconnect the connector and wire from the starter.
b) Remove the 2 bolts and starter.
Torque: 39 Nm (400 kgf-cm, 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 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:
- Take care not to damage the transfer adaptor oil seal with the transfer input gear spline.
- At the time of installation, please refer to the item.
- 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.