Installation
1. Place the gearbox on a gearbox jack.
2.
CAUTION: Make sure the box is not skewed.
CAUTION: Before installing the gearbox, check that the clutch assembly is not damaged.
NOTE: Do not install the box completely on the engine; leave a gap of 40 mm.
Install the gearbox with an assistant. Clean the contact surfaces of the parts.
3. Using a transmission jack, rotate the transmission to gain access to the shift mechanism.
4. Install the shift mechanism to the gearbox.
5.
CAUTION: Before installing the gearbox, check that the clutch assembly is not damaged.
Align the gearbox with the engine and install the gearbox.
6. NOTE: Transfer case housing shown removed for clarity.
Screw in 14 bolts of a transmission. Tighten the bolts with a tightening torque of 40 Nm.
7. Install the exhaust bypass pipe center support bracket. Tighten the bolts with a tightening torque of 25 Nm.
8. Establish a plait of electroconducting in a starting position on a transmission.
9. Install the left and right exhaust bypass pipe support brackets.
- Align the bypass exhaust pipe support bracket assembly.
- Tighten the bolts evenly with a tightening torque of 25 Nm.
11. Attach the wiring harness to the gearbox.
- Insert the wiring harness into the clamp.
- Connect electrical connectors.
- Screw in and tighten 2 bolts.
13. Attach the wiring harness to the transfer case.
- Tighten the bolts (tightening torque 25 Nm).
- Insert the wiring harness into the clamp.
15. Connect draft of a gear change.
- Clear the details.
- Lubricate the details.
- Install new o-rings.
- Install the clamp.
- Clear the details.
- Install a new O-ring.
- Install the clamp.
- Remove the hose clamp.
- Remove adhesive tape.
- Install the fastening clips.
19. Attach the fuel cooler. Insert the bolt and tighten it (tightening torque 10 Nm).
20. Install the 2 turbocharger support bracket bolts. Tighten the bolts (tightening torque 25 Nm).
21. Tighten the turbocharger support bracket nut. Tighten the nut with a tightening torque of 25 Nm.
22. Install the exhaust heat shield.
23. Remove air from the clutch system.
24. Install the front drive shaft. For more information refer to Front Driveshaft - 2.7L Diesel (47.15.02)
25. Remove the gearbox jack.
26. Install the lower engine protection. For more information refer to Motor Protection (76.10.50)
27.
CAUTION: To prevent damage to the pivot or boot, do not allow the drive shaft to be suspended.
Connect the drive shaft to the transfer case drive flange.
- Remove the mounting tape.
- Tighten Torx bolts (tightening torque 55 Nm).
- Align the center bearing support.
- Tighten the 2 driveshaft center bearing support bolts (tightening torque 30 Nm).
- Tighten the bolts (tightening torque 6 Nm).
- Tighten nuts (tightening torque 3 Nm).
31. Establish a protective cover of the gear lever.
32. Install the 2 shifter support bracket bolts. Tighten the bolts (tightening torque 25 Nm).
33. Establish the switch of system of optimization of operating modes of a suspension bracket and a steering. For more information, refer to Suspension performance optimization switch and car handling (86.65.11)
34. Connect a wire of weight of the storage battery.
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