1. Set the vehicle on a lift.
2. Open the front hood.
3. Disconnect the ground cable from battery.
4. Drain transmission gear oil completely. 
5. Remove the air intake chamber and intake boot.
6. Remove the air intake chamber stay.
7. Disconnect the following connector.
|
(A) |
Neutral position switch connector (Brown) |
|
(B) |
Back-up light switch connector (Gray) |
|
(C) |
High-low switch connector (Black) |
8. Disconnect the transmission radio ground terminal.
9. Disconnect the engine harness connectors, and then remove the engine hanger rear.
|
(A) |
Engine harness connectors |
|
(B) |
Engine hanger rear |
10. Remove the starter.
11. Remove the operating cylinder from the transmission, and suspend on a wire.
12. Remove the throttle body.
13. Remove the pitching stopper.
14. Remove the snap pin and clevis pin. (dual-range model)
15. Loosen the nut, and disconnect the cable from the cable bracket. (dual-range model)
|
(A) |
Snap pin |
|
(B) |
Clevis pin |
|
(C) |
Drive select cable |
16. Set the ST.
| ST 41099AC000 | ENGINE SUPPORT ASSY |
17. Lift up the vehicle.
18. Remove the front exhaust pipe.
19. Remove the rear exhaust pipe and muffler.
CAUTION:
When removing the exhaust pipes, make sure that each exhaust pipe does not drop off.
20. Remove the bolts which hold upper side of transmission to engine.
21. Remove the heat shield cover.
22. Remove the hanger bracket from the right side of transmission.
23. Remove the propeller shaft.
24. Remove the gear shift rod and the stay from the transmission.
(1) Disconnect the stay from the transmission.
(2) Disconnect the gear shift rod from the transmission.
|
(A) |
Stay |
|
(B) |
Gear shift rod |
25. Disconnect the stabilizer link from the front arm.
26. Remove the bolt securing the ball joint of the front arm to the housing, then separate the front arms and the housing.
|
(A) |
Front arm |
|
(B) |
Ball joint |
27. Using a crowbar, remove the left and right front drive shaft from the transmission.
|
(A) |
Crowbar |
28. Remove the bolts and nuts which hold lower side of transmission to engine.
29. Place the transmission jack under the transmission.
CAUTION:
Always support the transmission case with a transmission jack.
30. Remove the front crossmember and rear crossmember from the vehicle.
31. While lowering the transmission jack, tighten the turnbuckle of the ST, and incline the engine unit rearward.
32. Remove the transmission.
NOTE:
Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.
33. Separate the transmission assembly from the transmission cushion rubber.
1. Set the vehicle on a lift.
2. Open the front hood completely.
3. Remove the front wheels.
4. Disconnect the ground cable from battery.
5. Remove the air intake boot assembly.
6. Disconnect the following connector.
• Neutral position switch connector (Brown)
• Back-up light switch connector (Gray)
• High-low switch connector (black) (dual-range model)
|
(A) |
Neutral position switch connector (Brown) |
|
(B) |
High-low switch connector (Black) (dual-range model) |
|
(C) |
Back-up light switch connector (Gray) |
7. Disconnect the transmission radio ground terminal.
8. Remove the bolt and disconnect the engine harness connector.
9. Remove the engine harness connector from the engine hanger rear.
10. Remove the engine ground terminal, and remove the engine hanger rear.
11. Remove the starter.
12. Remove the operating cylinder from the transmission, and suspend on a wire.
13. Remove the throttle body.
14. Remove the pitching stopper.
15. Remove the secondary air combination valve LH bracket.
16. Set the ST.
| ST1 41099AA010 | ENGINE SUPPORT BRACKET |
| ST2 41099AA020 | ENGINE SUPPORT |
17. Remove the snap pin and clevis pin.
|
(A) |
Snap pin |
|
(B) |
Clevis pin |
18. Loosen the nut, and disconnect the cable from the cable bracket.
19. Remove the bolts which hold upper side of transmission to engine.
20. Lift up the vehicle.
21. Remove the under cover.
22. Drain transmission gear oil completely.
23. Remove the center exhaust pipe.
24. Remove the hanger bracket from the right side of transmission.
25. Remove the heat shield cover.
26. Remove the propeller shaft.
27. Remove the gear shift rod and the stay from the transmission.
(1) Disconnect the stay from the transmission.
(2) Disconnect the gear shift rod from the transmission.
|
(A) |
Stay |
|
(B) |
Gear shift rod |
28. Disconnect the stabilizer link from the front arm.
29. Remove the bolt securing the ball joint of the front arm to the housing, then separate the front arms and the housing.
|
(A) |
Front arm |
|
(B) |
Ball joint |
30. Using a crowbar, remove the left and right front drive shaft from the transmission.
|
(A) |
Crowbar |
31. Remove the bolts and nuts which hold lower side of transmission to engine.
32. Place the transmission jack under the transmission.
CAUTION:
Always support the transmission case with a transmission jack.
33. Remove the front crossmember and rear crossmember from the vehicle.
34. While lowering the transmission jack, tighten the turnbuckle of the ST, and incline the engine unit rearward.
35. Remove the transmission.
NOTE:
Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.
36. Separate the transmission assembly from the transmission cushion rubber.