Removal and Installation

REMOVAL





1. REMOVE TRANSMISSION SHIFT LEVER
a. Remove the front and rear console boxes and the rear console box cover.
b. Remove the 4 screws and front console box.
c. Remove the 4 screws and shift lever boot and retainer.
d. Cover the shift lever cap with a cloth.
e. Pressing down on the shift lever cap and rotate it counterclockwise to remove.
f. 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





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 FRONT AND REAR PROPELLER SHAFTS
5. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS
6. w/o One Touch 2-4 Selector System: DISCONNECT 4WD POSITION SWITCH CONNECTOR
7. w/ One Touch 2-4 Selector System: DISCONNECT L4 POSITION SWITCH CONNECTOR
8. DISCONNECT CLUTCH RELEASE CYLINDER
Remove the 2 bolts and release cylinder.
Torque: 12 Nm (120 kgf-cm, 9 ft. 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 Nm (490 kgf-cm, 35 ft. lbs.)





c. Remove the 3 bolts and bracket.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
d. Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
10. 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.)
11. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque: 18 Nm (185 kgf-cm, 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 Nm (185 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.)
13. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 65 Nm (660 kgf-cm, 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 Nm (730 kgf-cm, 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 adapter 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 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 oil seal.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, do the road test.