Transmission Assembly

TRANSMISSION ASSEMBLY

Removal and Installation (4WD)


COMPONENTS











NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL


CAUTION:
When removing the A/T assembly from engine, first remove the crankshaft position sensor (POS) from the A/T assembly.
1.Disconnect the negative battery terminal. Removal and Replacement.
2.Remove the A/T fluid level gauge.
3.Remove the front LH wheel and tire assembly. Service and Repair.
4.Remove the LH mud flap. Service and Repair.
5.Remove the LH fender protector. Service and Repair.





6.Remove the crankshaft position sensor (POS) from the A/T
assembly.

CAUTION:
- Do not subject it to impact by dropping or hitting it.
- Do not disassemble.
- Do not allow metal filings or foreign material to get on the sensor's front edge magnetic area.
- Do not place in an area affected by magnetism.
7.Remove the engine under cover using power tool.
8.Remove the front crossmember using power tool.
9.Remove the starter motor.
10.Remove the front and rear propeller shafts. Removal And Installation (front) and Removal And Installation (rear).
11.Remove the left and right front exhaust tubes. Exploded View.
12.Remove the shift selector control cable and bracket from the A/T.
13.Disconnect the fluid cooler tubes from the A/T assembly.

CAUTION:
Do not reuse copper sealing washers.
14.Remove the dust cover from the converter housing.





15.Turn the crankshaft to access and remove the four bolts for the drive plate and torque converter.

CAUTION:
When turning the crankshaft, turn it clockwise as viewed from the front of the engine.
16.Support the A/T assembly using a transmission jack.

CAUTION:
When setting the transmission jack, be careful not to allow it to collide against the drain plug.
17.Remove the nuts securing the insulator to the crossmember.
18.Remove the crossmember using power tool.
19.Tilt the transmission slightly to gain clearance between the body and the transmission, then disconnect the air breather hose.
20.Disconnect the following:
- A/T assembly harness connector
- 4LO switch connector
- Wait detection switch connector
- ATP switch connector
- Transfer control device connector
21.Remove the wiring harness from the retainers.
22.Remove the A/T fluid charging pipe.
23.Remove the A/T assembly to engine bolts using power tool.





24.Remove A/T assembly with transfer from the vehicle using Tool.
Tool number:- (J-47002)

CAUTION:
- Secure the torque converter to prevent it from dropping.
- Secure the A/T assembly to the transmission jack.
NOTE:
The actual special service Tool may differ from Tool shown.
25.Remove the transfer from the A/T assembly. Removal And Installation.

INSPECTION

Installation and Inspection of Torque Converter





- After inserting the torque converter to the transmission, be sure to check dimension (A) to ensure it is within the reference value limit.
Dimension (A): 25.0 mm (0.98 in) or more

INSTALLATION

Installation is in the reverse order of removal.

CAUTION:
- When replacing an engine or transmission you must make sure the dowels are installed correctly during re-assembly.
- Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of drivetrain components.
- Do not reuse O-rings and copper sealing washers. Refer to "COMPONENTS".
- When turning crankshaft, turn it clockwise as viewed from the front of the engine.
- After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transmission rotates freely without binding.
- When tightening the bolts for the torque converter while securing the crankshaft pulley bolt, be sure to confirm the tightening torque of the crankshaft pulley bolt. Exploded View.





- When installing transmission to the engine, tighten the bolts to the specified torque using sequence shown.
Transmission bolts: 75 Nm (7.7 kg-m, 55 ft-lb)





- When installing the drive plate to torque converter bolts, align the positions of bolts for drive plate with those of the torque converter and temporarily tighten the bolts. Then tighten the bolts to the specified torque.
- After completing installation, fill A/T with fluid and check for fluid leaks, fluid level, and the positions of A/T. Checking, and "Inspection and Adjustment".