Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Release the oxygen sensor connector from the bracket on the left valve cover, disconnect the connector.
2. Unscrew the 4 nuts securing the left exhaust manifold to the cylinder head.
3. Remove the exhaust manifold and discard its gaskets.
4. Loosen the nut securing the heat shield to the transfer case.
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5. Loosen the nut securing the heat shield to the rear axle drive shaft housing.
6. Unscrew the 2 heat shield mounting bolts and remove the shield.
7. Disconnect the breather hose from the transfer case housing.
8. Loosen the clamp and disconnect the cooling system hoses from the transfer case.
9. Unscrew the bolt securing the lower engine crossmember to the transfer case bracket.
10. Remove the lower engine crossmember. The 'TOP' mark should be at the top.
11. Remove the 3 bolts securing the transfer case bracket to the pan.
12. Unscrew the 2 bolts securing the transfer case bracket to the front engine plate.
13. Remove the 5 bolts securing the bracket to the transfer case.
14. Remove the bracket.
15. Unscrew the 4 transfer case mounting bolts.
16. With the help of a partner, separate the transfer case from the gearbox and remove the transfer case.
17. Remove the O-ring from the transfer case and discard it.
18. Remove the two bolts securing the torque converter hatch cover.
19. Remove the hatch cover.
20. Mark the relative positions of the drive disk and torque converter for subsequent assembly.
21. Unscrew the 4 bolts securing the drive disk to the torque converter.
22. Unscrew the bolt securing the bracket of the cooling system hose going to the transfer case. Remove the bracket.
23. Unscrew the bolts securing the LRT-44-026 lifting eye to the gearbox and remove the eye.
24. Unscrew the 3 bolts securing the starter to the gearbox, noting that the left one also serves to secure the crankshaft position sensor connector.
25. Remove the starter.
26. Disconnect the 2 fittings from the heat exchanger and discard the O-rings.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
27. Loosen the two clamps and disconnect the cooling system hoses from the transmission heat exchanger.
28. Unscrew the heat exchanger mounting bolts.
29. Remove the working fluid cooling heat exchanger.
30. Loosen the bolt securing the crankshaft position sensor to the gearbox, release the sensor and move it to the side.
31. Unscrew the bolt and nut securing the gearbox to the engine, located next to the crankshaft position sensor
32. Attach the lifting eyes to the gearbox.
33. Attach the rigging equipment to the eyes.
34. Unscrew the 2 bolts securing the gearbox to the engine.
35. Remove the 2 upper transmission-to-engine mounting bolts.
36. Release the gearbox from the two guide pins.
37. Remove the gearbox.
38. Install the torque converter retaining plate and secure it with screws.
Installation
1. Remove the torque converter retaining plate.
2. Check that the torque converter is fully seated on the oil pump drive by measuring dimension 'A' shown in the figure. Dimension A = 4 mm.
3. Wipe the mating surfaces of the engine and gearbox, the dowel pins and the dowel seats.
4. Install the gearbox.
5. Screw in the gearbox mounting bolts to the engine and tighten them to a torque of 85 Nm.
6. Remove the rigging chains.
7. Wipe the crankshaft position (CKP) sensor and mating surfaces.
8. Install the crankshaft position sensor, screw in its mounting bolt and tighten to a torque of 9 Nm.
9. Install the heat exchanger, tighten the M12 bolts to a torque of 85 Nm, the M8 bolts to a torque of 25 Nm.
10. Connect the hoses to the heat exchanger.
11. Wipe the heat exchanger fittings.
12. Lubricate new sealing rings with clean working fluid and install them on the heat exchanger hoses.
FILLING CAPACITIES, LIQUIDS AND OILS, Lubrication system.
13. Connect the heat exchanger hoses to the gearbox and tighten the union nuts to a torque of 18 Nm.
14. Clean the starter and mating surfaces from dirt.
15. Install the starter on the gearbox, move the crankshaft position sensor connector bracket to the mounting location, screw in the bolts and tighten them to a torque of 45 Nm.
16. Attach the LRT-44-026 lifting eyes to the gearbox using the gearbox bracket mounting bolts.
17. Install the transfer case heat exchanger hose mounting bracket, screw in the mounting bolt and tighten it to a torque of 25 Nm.
18. Align the position marks on the drive disc and torque converter.
19. Screw in the bolts securing the drive disk to the torque converter and tighten them to a torque of 45 Nm.
20. Wipe the torque converter hatch cover.
21. Install the hatch cover, screw in the bolts and tighten them to a torque of 9 Nm.
22. Clean the mating surfaces of the transfer case and gearbox.
23. Lubricate the new sealing ring and install it in place.
24. With the help of a partner, install the transfer case.
25. Screw in the bolts securing the transfer case to the gearbox and pull their mating surfaces together without tightening the bolts completely.
26. Install the transfer case bracket and tighten the mating surfaces together.
27. Finally tighten the bolts securing the transfer case to the gearbox. Tightening torque 80 Nm.
28. Finally tighten the transfer case bracket mounting bolts in the following order: tighten the 5 bracket mounting bolts to the transfer case to a torque of 50 Nm, 2 bracket mounting bolts to the front engine mount to a torque of 50 Nm, 3 bracket mounting bolts to the oil pan to a torque of 45 Nm.
29. Install the lower engine mount crossmember with the 'TOP' mark facing up. Screw in the bolt, but do not tighten it completely.
30. Connect the cooling system hoses and secure them with clamps.
31. Connect the breather hose to the transfer case.
32. Install the heat shield of the manifold and tighten the nut securing it to the rear axle drive shaft housing using your finger.
33. Screw in the heat shield mounting bolts to the transfer case bracket and tighten them to a torque of 9 Nm.
34. Fit the heat shield mounting nut to the transfer case and tighten it to 45 Nm.
35. Finally tighten the nut securing the heat shield to the rear axle drive shaft housing and tighten it to a torque of 25 Nm.
36. Wipe the exhaust manifold and the mating surface on the cylinder head.
37. Install the exhaust manifold gasket.
38. Install the exhaust manifold, fit the nuts and tighten them to 45 Nm, starting from the center.
39. Connect the oxygen sensor connector and secure it to the bracket.
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