Removal and Installation

REMOVAL
1. REMOVE TRANSFER SHIFT LEVER
a. Remove the transfer shift lever knob.
b. Remove the upper console panel.





c. Remove the 4 bolts and shift lever boot.





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

HINT: Shift the transfer shift lever to the "H" position and one touch 2 - 4 selector switch "OFF."

2. REMOVE PROTECTOR
Remove the 4 bolts and protector.
3. RAISE VEHICLE AND DRAIN TRANSFER OIL
4. REMOVE LH AND RH FRONT EXHAUST PIPES
5. REMOVE FRONT AND REAR PROPELLER SHAFTS





6. REMOVE CROSSMEMBER
a. Support the transmission rear side with a transmission jack.
b. Remove the 4 set bolts of the engine rear mounting.
c. Remove the 4 bolts, nuts and crossmember.
7. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the transfer adaptor.
8. DISCONNECT VEHICLE SPEED SENSOR, NEUTRAL POSITION SWITCH, L4 POSITION SWITCH, MOTOR ACTUATOR, NO. 1 AND NO. 2 4WD POSITION SWITCH CONNECTORS





9. REMOVE TRANSFER FROM TRANSMISSION
a. Support the transfer with another transmission jack.
b. Remove the 8 transfer mounting bolts.
c. Pull out the transfer from the transfer adaptor down and toward the rear.

INSTALLATION
1. RAISE VEHICLE





2. INSTALL TRANSFER
Raise the transfer and install it to the transfer adaptor with the 8 transfer mounting bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)

NOTICE: Take care not to damage the lip of the transfer adaptor rear oil seal with the transfer input shaft.

3. CONNECT VEHICLE SPEED SENSOR, NEUTRAL POSITION SWITCH, L4 POSITION SWITCH, MOTOR ACTUATOR, NO. 1 AND NO. 2 4WD POSITION SWITCH CONNECTORS.





4. INSTALL ENGINE REAR MOUNTING
Install the engine rear mounting to the transfer adaptor with the 4 bolts.
Torque: 65 Nm (650 kgf-cm, 48 ft. lbs.)
5. INSTALL CROSSMEMBER
a. Install the crossmember with the 4 bolts and nuts.
Torque: 72 Nm (740 kgf-cm, 53 ft. lbs.)
b. Install the 4 set bolts of the engine rear mounting.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
c. Remove the transmission jacks.
6. INSTALL FRONT AND REAR PROPELLER SHAFTS
7. INSTALL LH AND RH FRONT EXHAUST PIPES





8. FILL TRANSFER OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.2 liters (1.3 US qts., 1.1 Imp. qts.)
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
9. INSTALL PROTECTOR
Install the protector with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
10. INSTALL TRANSFER SHIFT LEVER
a. Lower the vehicle.





b. Apply MP grease to the tip of the transfer shift lever.
c. Pressing down on the transfer shift lever cap, and using pliers, install the snap ring.





d. Install the shift lever boot with the 4 bolts.
Torque: 7.0 Nm (70 kgf-cm, 61 inch lbs.)
e. Install the upper console panel.
f. Install the transfer shift lever knob.
11. DO ROAD TEST
Check for abnormal noise and smooth shifting.