Removal and Replacement

REMOVAL
1. REMOVE ATF LEVEL GAUGE
2. REMOVE ENGINE UNDER COVER
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)








3. DISCONNECT THROTTLE CABLE
a. Loosen the nut and disconnect the cable.
b. Separate the throttle cable from the clamp.





4. REMOVE NO.1 FAN SHROUD
Remove the 4 bolts and No.1 fan shroud.
5. REMOVE TRANSMISSION SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER





a. Remove the 2 bolts, 4 screws and rear console box.





b. w/ One touch 2-4 selector: Remove the 3 screws and front console box with the transfer shift lever knob.





c. w/o One touch 2-4 selector: Remove the 2 screws and front console box with the transfer shift lever knob.
d. Disconnect the connectors.





e. Remove the nut and washer, and disconnect the shift control rod.





f. Disconnect the connector and remove the 8 screws and transmission shift lever assembly.





g. Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer.

HINT: At the time of installation, please refer to the item. Apply MP grease to the transfer shift lever.

6. REMOVE OIL FILLER PIPE
a. 3RZ-FE: Remove the 2 bolts and oil filler pipe with the O-ring.

HINT: At the time of installation, please refer to the item. Replace the used O-ring with a new one.

b. 5VZ-FE: Remove the bolt and oil filler pipe with the O-ring.

HINT: At the time of installation, please refer to the item. Replace the used O-ring with a new one.

7. REMOVE FRONT AND REAR PROPELLER SHAFT
8. REMOVE EXHAUST PIPE

HINT: At the time of installation, please refer to the item. Replace the used gaskets and nuts with new ones.

9. DISCONNECT CONNECTOR FROM TRANSMISSION
a. Disconnect the No. 1 and No.2 vehicle speed sensor connector.
b. Disconnect the solenoid connector.
c. Disconnect the transfer neutral position switch connector.
d. Disconnect the transfer L4 position switch connector.
e. Disconnect the 4WD position switch connector.
10. DISCONNECT OIL COOLER PIPE








a. Remove the 3 bolts and clamps.





b. Loosen the 2 union nuts and disconnect the 2 oil cooler pipes.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
11. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR
12. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR








13. REMOVE STARTER
a. Remove the nut and disconnect the connector and terminal.
b. Remove the 2 bolts and starter.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
14. REMOVE 4 STABILIZER BAR BRACKET MOUNTING BOLTS
15. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT





a. 3RZ-FE: Remove the 2 nuts and bolts.
Remove the 2 bolts and flywheel housing under cover.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)





b. 5VZ-FE: Remove the 4 bolts and flywheel housing under cover.
Torque: 37 Nm (185 kgf-cm, 13 ft. lbs.)





c. Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley bolt with a wrench.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)

HINT: At the time of installation, please refer to the item. First install green colored bolt and then 5 other bolts.

16. REMOVE FRONT DIFFERENTIAL REAR MOUNTING CUSHION





a. Using a hexagon wrench (12 mm), remove the nut.
Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.)
b. Lift up the front differential with a support stand.

NOTICE: Be careful not to touch the torque converter clutch housing and front differential companion flange.





c. Remove the 2 rear mounting cushion mounting bolts.
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)





17. REMOVE CROSSMEMBER
a. Support the transmission rear side with a support stand.
b. Remove the 4 engine rear mounting bolts.
Torque: 18.5 Nm (189 kgf-cm, 14 ft. lbs.)
c. Remove the 4 nuts, bolts and crossmember.
Torque: 72 Nm (734 kgf-cm, 53 ft. lbs.)
d. Support the transmission with a transmission jack.
18. REMOVE TRANSMISSION
a. Lower the transmission rear side.
b. Separate the wire harness from the transmission.





c. 3RZ-FE: Remove the 4 bolts and transmission.
Torque: 71 Nm (730 kgf-cm, 53 ft. lbs.)





d. 5VZ-FE: Remove the 6 bolts and transmission.
Torque: 71 Nm (730 kgf-cm, 53 ft. lbs.)

INSTALLATION





1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION
Using calipers and a straight edge, measure the distance from the installed surface of the transmission housing to the installed surface of the torque converter clutch.
Correct distance:
3RZ-FE: More than 31.75 mm (1.2500 inch)
5VZ-FE: More than 17.95 mm (0.7067 inch)
2. INSTALL TRANSMISSION
Installation is in the reverse order of removal.

HINT:
- After installation, adjust the shift lever position and throttle cable.
- Fill and check fluid lever.