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.

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

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

HINT: At the time of installation, please refer to the item. 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 FRONT AND REAR PROPELLER SHAFTS
5. DISCONNECT VEHICLE SPEED SENSOR, BACK-UP LIGHT SWITCH AND 4WD POSITION SWITCH CONNECTORS
6. DISCONNECT CLUTCH RELEASE CYLINDER
Remove the 2 bolts and disconnect the release cylinder.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
7. REMOVE FRONT EXHAUST PIPE





a. Remove the 2 nuts, gasket and oxygen sensor.
b. Remove the 2 bolts, nuts and gasket.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





c. Remove the 2 set bolts of the front exhaust pipe bracket.
Torque:
71 Nm (720 kgf-cm, 52 ft. lbs.)
72 Nm (730 kgf-cm, 53 ft. lbs.)
d. Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
8. REMOVE REAR END PLATE
Remove the 4 bolts, 2 nuts and rear end plate.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)





9. REMOVE CROSSMEMBER
a. Support the transmission rear side.
b. Remove the 4 set bolts of the engine rear mounting.
Torque: 18 Nm (183 kgf-cm, 13 ft. lbs.)
c. Disconnect the O-ring and remove the 4 bolts, nuts and crossmember.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
10. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
11. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.





12. 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.)
13. REMOVE TRANSMISSION WITH TRANSFER
a. Remove the 3 transmission mounting bolts from the engine.
Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.)
b. Pull out the transmission with the transfer down and toward the rear.





14. REMOVE TRANSFER FROM TRANSMISSION
a. Remove the 8 rear mounting bolts of the transfer adapter.
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 adapter rear oil seal with the transfer input gear spline.

HINT: At the time of installation, please refer to the item. Apply MP grease to the lip of the adapter rear oil seal.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, do the road test.