Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Secure the hood in a vertical position.
3. Remove the air intake hoses.
DIESEL ENGINE FUEL SUPPLY SYSTEM, REPAIR WORK, Air intake system ducts.
4. Remove the battery tray.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Support tray - battery.
5. Remove the starter.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Starter - Td4 engine.
6. Remove the transfer case (IRD).
TRANSFER CASE, REPAIR WORK, Transfer case: models with Td4 engine.
7. Install the LRT-54-026 tool onto the drive shaft inner joint. Use a lever to release the left inner joint from the gearbox.
8. With the help of a partner, move the hub outward and remove the left drive shaft from the gearbox.
CAUTION: When removing the shaft, keep it horizontal to avoid damaging the differential seal.
9. Remove and discard the drive shaft retaining ring.
10. Using the LRT-37-050 tool, disconnect the gear selector rod from the gear selector shaft.
11. Disconnect the reversing light switch connector.
12. Using the LRT-37-051 tool, disconnect and remove the clutch drive pipe.
13. Remove the bolt and disconnect the ground bus from the gearbox.
14. Disconnect the connector from the first gear engagement contact sensor.
15. Attach the rigging chains to the eyes and lift the engine to remove its weight from the supports.
16. Remove the through bolt securing the gearbox bracket to the left support.
17. Lower the box so that it moves away from the support.
18. Unscrew the 4 bolts securing the left support bracket to the gearbox and remove the bracket.
19. To facilitate subsequent assembly, mark the relative positions of the gear selector lever and the gear selector rod.
20. Using the LRT-37-049 puller, carefully remove the cylindrical pin connecting the gear selector lever to the rod.
21. Remove the lever from the rod.
22. Install the lifting eye on the gearbox and secure it with a bolt.
23. Attach the rigging chains to the eye and hang the gearbox.
24. Unscrew the bolt securing the cover to the gearbox.
25. Unscrew the 7 bolts securing the gearbox to the engine.
26. Release the gearbox from the two guide pins.
27. Lower the gearbox to the floor.
28. If necessary, remove the cover from the gearbox
Installation
1. Clean the gearbox cover.
2. Check that the cover is on the mounting pins.
3. Wipe the mating surfaces of the engine and gearbox, the dowel pins and the dowel seats.
4. Attach the rigging chains to the eye and hang the gearbox.
5. Raise the gearbox and slide it onto the mounting pins. Screw in the gearbox-to-engine mounting bolts and tighten them to 85 Nm.
6. Screw in the cover mounting bolt and tighten it. Tightening torque 10 Nm.
7. Wipe the gear selector shaft and gear selector lever.
8. Install the lever on the rod and align the holes for the cylindrical pin.
9. Install the LRT-37-049 mandrel, press the new pin into the gear selection rod and remove the mandrel. Check the operation of the gear selection mechanism.
10. Install the bracket on the gearbox, screw in the bolts and tighten them to a torque of 85 Nm.
11. Raise the engine with the gearbox, move the gearbox bracket to the installation location.
12. Insert the through bolt securing the left engine mount to the gearbox and tighten it to a torque of 100 Nm.
13. Remove the gearbox rigging.
14. Disconnect the rigging chains from the engine.
15. Connect the connector to the first gear engagement contact sensor.
16. Connect the connector to the reversing light switch.
17. Place the ground wire on the gearbox and tighten the mounting bolt. Tightening torque 25 Nm.
18. Connect the clutch pipe quick release connector.
19. Install a new snap ring onto the end of the left drive shaft.
20. With the help of a partner, insert the left drive shaft into the gearbox, holding it at the correct angle to avoid damaging the gearbox seal.
21. Install the transfer case (IRD).
TRANSFER CASE, REPAIR WORK, Transfer case: models with Td4 engine.
22. Reinstall the starter.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Starter - Td4 engine.
23. Reinstall the battery tray.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Support tray - battery.
24. Install the air intake hoses.
DIESEL ENGINE FUEL SUPPLY SYSTEM, REPAIR WORK, Air intake system ducts.
25. Connect the negative battery terminal.
26. Untie the hood and close it.
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