1. Replace the differential side retainer oil seal. 
NOTE:
Be sure to replace the differential side retainer oil seal after removing the front drive shaft.
2. Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case.
CAUTION:
Do not apply excessive load or impact to the transmission case.
3. Install the transmission cushion rubber to the transmission, and tighten the bolt (A).
4. Install the transmission cushion rubber to the center crossmember, and tighten the nut (B).
Tightening torque:
Bolt (A)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
Nut (B)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
• AWD model
• FWD model
5. Install the transmission onto the engine.
(1) Lift up the transmission gradually using a transmission jack.
(2) Engage at the spline section.
CAUTION:
Be careful not to hit the main shaft against the clutch cover.
6. While raising the transmission jack, loosen the turnbuckle of the ST, and set the engine unit to the original position.
7. Install the front crossmember and rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)
8. Take out the transmission jack.
9. Tighten the bolts and nuts which hold the lower side of transmission to the engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
10. Connect the transmission to the engine.
(1) Install the starter.
(2) Tighten the bolts which hold the upper side of the transmission to the engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
11. Remove the ST.
12. Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
13. Install the throttle body.
14. Lift up the vehicle.
15. Install the front drive shaft into the transmission.
| ST 28399SA010 | OIL SEAL PROTECTOR |
16. Insert the front arm ball joint into the housing lower part, and tighten the mounting bolt.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
|
(A) |
Front arm |
|
(B) |
Ball joint |
17. Attach the stabilizer link to the front arm.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
18. Attach the gear shift rod and stay.
(1) Attach the gear shift rod to the transmission.
Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)
|
(A) |
Stay |
|
(B) |
Gear shift rod |
(2) Install the stay to the transmission bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
19. Install the propeller shaft.
20. Install the heat shield cover.
21. Install the hanger bracket to the transmission.
22. Install the rear exhaust pipe and muffler.
23. Install the front exhaust pipe.
24. Install the under cover.
25. Install the operating cylinder.
Tightening torque:
37 N·m (3.8 kgf-m, 27.3 ft-lb)
26. Attach the transmission drive select cable. (dual-range model)
|
(A) |
Snap pin |
|
(B) |
Clevis pin |
|
(C) |
Drive select cable |
27. Install the transmission radio ground terminal.
Tightening torque:
13 N·m (1.3 kgf-m, 9.6 ft-lb)
28. Install the engine hanger rear, and then connect the engine harness connector.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
|
(A) |
Engine harness connectors |
|
(B) |
Engine hanger rear |
29. Connect the following connectors.
|
(A) |
Neutral position switch connector (Brown) |
|
(B) |
Back-up light switch connector (Gray) |
|
(C) |
High-low switch connector (Black) (dual-range model) |
30. Install the air intake chamber stay.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
31. Install the air intake chamber and intake boot.
32. Connect the battery ground terminal.
33. Remove the lift arm from vehicle.
1. Replace the differential side retainer oil seal.
NOTE:
Be sure to replace the differential side retainer oil seal after removing the front drive shaft.
2. Install the transmission cushion rubber to the transmission assembly, and tighten bolt (A).
3. Install the transmission cushion rubber to the center crossmember, and tighten the nut (B).
Tightening torque:
Bolt (A)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
Nut (B)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
• AWD model
• FWD model
4. Install the transmission onto the engine.
(1) Lift up the transmission gradually using a transmission jack.
(2) Engage at the spline section.
NOTE:
Be careful not to hit the main shaft against the clutch cover.
5. While raising the transmission jack, loosen the turnbuckle of the ST, and set the engine unit to the original position.
6. Install the front crossmember and rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)
7. Take out the transmission jack.
8. Tighten the bolts and nuts which hold the lower side of transmission to the engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
9. Connect the transmission to the engine.
(1) Install the starter.
(2) Tighten the bolts which hold the upper side of the transmission to the engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
10. Remove the ST.
11. Install the secondary air combination valve LH bracket.
Tightening torque:
T1: 13 N·m (1.3 kgf-m, 9.6 ft-lb)
T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
12. Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
13. Install the throttle body.
14. Lift up the vehicle.
15. Install the front drive shaft into the transmission.
| ST 28399SA010 | OIL SEAL PROTECTOR |
16. Insert the front arm ball joint into the housing lower part, and tighten the mounting bolt.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
|
(A) |
Front arm |
|
(B) |
Ball joint |
17. Attach the stabilizer link to the front arm.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
18. Attach the gear shift rod and stay.
(1) Attach the gear shift rod to the transmission.
Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)
|
(A) |
Stay |
|
(B) |
Gear shift rod |
(2) Install the stay to the transmission bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
|
(A) |
Stay |
|
(B) |
Transmission bracket |
19. Install the propeller shaft.
20. Install the heat shield cover.
21. Install the hanger bracket to the transmission.
22. Install the center exhaust pipe.
23. Install the under cover.
24. Lower the vehicle.
25. Install the operating cylinder.
Tightening torque:
37 N·m (3.8 kgf-m, 27.3 ft-lb)
26. Install the cable to the cable bracket, and tighten the nut.
27. Install the snap pin and the clevis pin.
|
(A) |
Snap pin |
|
(B) |
Clevis pin |
28. Install the engine hanger rear and engine ground terminals.
Tightening torque:
T1: 16 N·m (1.6 kgf-m, 11.8 ft-lb)
T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
29. Install the engine harness connector to the engine hanger rear, connect the harness connector, and install the harness connector bracket.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
30. Install the transmission radio ground terminal.
Tightening torque:
13 N·m (1.3 kgf-m, 9.6 ft-lb)
31. Connect the following connectors.
|
(A) |
Neutral position switch connector (Brown) |
|
(B) |
High-low switch connector (Black) (Dual-range model) |
|
(C) |
Back-up light switch connector (Gray) |
32. Install the air intake boot assembly.
33. Install the front wheels.
34. Connect the battery ground terminal.
35. Remove the lift arm from vehicle.