REMOVAL AND INSTALLATION <4WD>


Pre-removal and Post-installation Operations
  • Transmission Control Lever Assembly and Transfer Control Lever Assembly <V5M21, V5MB1> Removal and Installation (Refer to ).
  • Transmission Oil Draining and Refilling (Refer to ).
  • Transfer Oil Draining and Refilling (Refer to ).
  • Under Skid Plate and Engine Room Under Cover Front Removal and Installation (Refer to GROUP 51 - Under Cover ).
  • Front and Rear Propeller Shaft Removal and Installation (Refer to GROUP 25 - Propeller Shaft ).
  • Catalytic Converter <4N1> Removal and Installation (Refer to GROUP 17 - Catalytic Converter ).
  • Exhaust Front Pipe <4G6, 4D5> or Exhaust Centre Pipe <4N1> Removal and Installation (Refer to GROUP 15 - Front Exhaust Pipe and Main Muffler ).
  • Clutch Release Cylinder Assembly and Clutch Damper Assembly Removal and Installation (Disconnect the connection with transmission only and do not disconnect the clutch line.) (Refer to GROUP 21A - Clutch Release Cylinder Assembly <Vehicles without Clutch Damper Assembly> or <Vehicles with Clutch Damper Assembly>).
  • Transfer Mount Bracket Assembly Removal and Installation (Refer to GROUP 32 - Transfer Mounting ).
  • Chassis frame crossmember and Rear engine support insulator Removal and Installation (Refer to GROUP 32 - Rear Engine Mounting ).





Removal steps


1.
 Transmission harness connector connection


·
 Support the transmission with a transmission jack


2.
 Bell housing cover


3.
 Transmission assembly lower part coupling bolts


4.
 Front exhaust pipe bracket


5.
 Transmission assembly upper part coupling bolts
<<A>>
·
 Starter mounting bolt


6.
 Transmission assembly




Removal steps


1.
 Transmission harness connector connection


2.
 Transfer harness connector connection


3.
 Air breather hose


4.
 Bracket


5.
 Under guard
<<A>>
·
 Starter mounting bolt
<<B>>
·
 Supporting the engine (during removal)
<<C>>
6.
 Transmission assembly


7.
 Transmission


8.
 Transfer

REMOVAL SERVICE POINTS

<<A>> STARTER MOUNTING BOLT REMOVAL
Remove the starter with its connector connected. Keep the starter fixed to the engine side (Refer to GROUP 16 - Starter Motor Assembly ).

<<B>> SUPPORTING THE ENGINE <V6M5A>

caution Support the engine assembly by inserting a wooden piece between the front suspension front crossmember assembly and the engine oil pan to prevent the engine assembly from being tilted significantly when the transmission assembly is separated from the engine assembly.

<<C>> TRANSMISSION ASSEMBLY REMOVAL <V6M5A>

1.Place a 10-mm thick wooden piece on the transmission jack attachment (MB991927) before attaching it to the transfer.
2.Place the transmission assembly on the transmission jack attachment (MB991927).
3.
caution Remove the transmission, being careful that the adapter does not touch the vehicle body.
Remove the transmission assembly.