Special tool(s)
 | Powertrain Jack Assembly HTJ1200-02 |
 | Puller, slider 308-652 |
 | Impact puller 100-012 |
 | Impact Puller Adapter 100-012-05 |
Removal
1. Open the front door.
2. Remove the front seat cushion assembly.
For more information, refer to the chapter: Front seat cushion (501-10 Seat, Removal and installation).
3. Remove the battery cover. Release the clamp.
4. Disconnect the ground wire from the battery.
For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).
5. Remove the center floor console.
For more information, please refer to the chapter: Floor Console (501-12 Instrument panel and console, Removal and installation).
6. Remove the carpet from the transmission cover panel.
7. Release the gear shift boot.
- Release the gear shift boot from the transmission tunnel.
- Release the shift lever boot from the clips on the high-low range selector lever.
8.
WARNING: The gearshift knob releases suddenly, so turn away when removing. Failure to follow this instruction may result in personal injury.
Remove the upper gear shift lever.
9. Remove the gear shift lever boot.
10. Disconnect the electrical connector from the reverse light switch.
11. Open the hood to provide access.
12. Remove the turbocharger heat shield. Remove the five bolts.
13. Remove the four catalytic converter mounting studs.
14.
WARNING: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.
Raise the vehicle and place supports underneath it.
15. Release the high-low range selector link ball joint from the transfer case.
16. Lower the vehicle.
17. Open the front door.
18. Remove the foam padding from around the perimeter of the shift levers.
19. Remove the four bolts securing the high-low range lever.
20. Remove the high-low range selector lever.
21. Remove the four bolts securing the gear selector housing.
22.
NOTE: Left side shown, right side similar.
Remove the chassis crossmember. Unscrew 8 bolts.
23. Remove the front propeller shaft.
For more information, refer to the chapter: Front Propeller Shaft (205-01 Cardan shaft, Removal and installation).
24. Unscrew the two nuts securing the catalytic converter to the intermediate pipe.
25. Remove the two bolts securing the catalytic converter support bracket.
26. Remove the catalytic converter.
27. Unscrew the nuts securing the rear pipe with the muffler to the intermediate pipe.
28. Remove the intermediate pipe and muffler.
29. Move the rear section of the propeller shaft.
- Mark the position of the drive shaft relative to the pinion flange.
- Remove the nuts securing the rear section of the propeller shaft to the transfer case.
30. Using a suitable clamp, secure the rear section of the driveshaft to the chassis.
31. Remove the parking brake drum. Remove the screw.
32. Remove the parking brake assembly and tie it to the side.
33. Disconnect the electrical connector of the electronic speedometer drive on the transfer case.
34. Loosen the nut and disconnect the left ground wire from the transfer case.
35. Remove the bolt securing the right ground wires from the transfer case.
36. Move the high-low range detection switch electrical connector away from the transfer case. Disconnect the high-low range detection switch electrical connector.
37. Disconnect the differential lock sensor electrical connector. Release the electrical connector from the bracket.
38. Release the breather line from the transfer case.
- Remove the bolt.
- Remove and discard the two sealing washers.
39. Loosen the nut and remove the bolt securing the transmission wiring harness bracket and move the wiring harness.
40. Release the electrical connector and transmission wiring harness bracket from the clip on the right side of the transmission.
41. Remove the transmission wiring harness retaining clip from the left side of the transmission.
42. Remove the transmission wiring harness retaining clip from the right side of the transmission.
43. Remove the transmission wiring harness retaining clip from the top of the transmission.
44. Remove the nut and bolt securing the clutch slave cylinder hose support bracket. Install a suitable clamp on the clutch slave cylinder hose.
45.
CAUTION: Plug all openings. Use new caps.
Disconnect the hose from the clutch slave cylinder.
- Remove the clutch slave cylinder tube clamp.
- Remove the sealing ring and dispose of it.
46. Install special tool HTJ1200-02 to the gearbox and transfer case.
47. Remove the left support and the gearbox support bracket. Unscrew the nuts and bolts securing the left support and the gearbox support bracket.
48. Remove the right transfer case support bracket. Unscrew the nuts and bolts securing the right support and the transfer case support bracket.
49. Remove the front crankcase section bolts.
50. Remove the gearshift housing.
- Move the transmission to gain access to the shift housing.
- Remove from under the car.
- Remove the rubber seal.
51.
CAUTION: Before lowering the HTJ1200-02, move the gearbox away from the clutch by 30 mm to prevent damage to the gearbox.
Remove the gearbox and transfer case from the vehicle.
52.
NOTE: Do not perform further disassembly if the component is removed only for access.
Remove the gearbox from the special tool.
53. With the help of an assistant, remove the transfer case.
- Remove 4 bolts.
- Unscrew 2 nuts.
54. Remove the gearbox console housing. Unscrew 10 bolts.
55. Remove the gearbox extension shaft cover.
- Remove the clamp.
- Remove the cover.
56. Remove the seal.
57. Using special tools, remove the gearbox extension shaft.
58. Remove the reversing light switch.
59. Remove the clutch slave cylinder.
- Remove the connecting tube retainer.
- Remove the connecting tube.
- Remove 3 bolts.
60. Remove the gear shift fork mounting nut.
61. Using the special tool, remove the gear shift fork. Unscrew the stud.
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