DRIVE TRAIN

Drive Train

Transmission Assembly

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the transmission fluid.
3. Remove or disconnect the following:
   • Negative battery cable
   • Transmission and transfer case shift lever assembly. On manual transmissions
   • Transfer case protector, if equipped
   • Front exhaust pipe from the 2 exhaust manifolds, then disconnect it from the intermediate pipe/catalytic converter (make certain to retain the bolts and nuts for reassembly).
   • Rear driveshaft at both the rear axle and the transfer case flanges. Matchmark for reassembly.
   • Front driveshaft from the front axle, by sliding it forward, plug the transfer case to prevent residual fluid leakage. On 4-wheel drive vehicles
   • Dust seal from the rear extension housing.
   • Ground cables
   • 4WD indicator light switch connector
   • Pulse generator connector
   • Speed Sensor Connector
   • Oxygen (O2S) sensor connector
   • Back-up light switch connector
   • HI/LO detection switch connector
   • Center differential lock detection switch connection.

   There may be others depending on the particular year, model and engine with which the vehicle came equipped.

4. Remove or disconnect the following:
   • Speedometer cable out of the transmission
5. On manual transmissions:
6. Remove or disconnect the following:
   • Clutch cylinder heat protector
   • Clutch release cylinder (with the clutch hose connected to it) from the transmission. Suspend it from the body by using a piece of wire or a similarly safe method.
   • Starter motor and the heat shield
7. On automatic transmissions:
8. Remove or disconnect the following:
   • Bolts attaching the torque converter to the flexplate
   • Dipstick
   • Fluid cooling lines
   • Shift linkage at the transmission
9. Place a floor jack and a block of wood below the engine oil pan.
10. Lift the floor jack under the engine just until the weight of the engine is taken onto the jack — the engine should only barely be lifted by the jack.
11. Use a transmission jack or second floor jack to place under the transmission. Don't support the transmission yet, only lift the jack until it is slightly below the transmission.
12. Remove or disconnect the following:
    • Left-hand and right-hand side transmission stays from the front of the transmission, if equipped
    • Bell housing lower cover
    • Transfer case mounting bracket, if equipped
13. Lift the floor jack up until the transmission is being slightly supported by it.
14. Remove or disconnect the following:
    • Transmission-to-crossmember bolts. Lift the jack about ¹⁄₄ in. (6mm) off of the crossmember support.
    • Crossmember from the vehicle
    • Transmission mounting blots. Pull the transmission away from the engine and lower it from the vehicle.

    To install:

15. Lift the transmission and transfer assembly into position with the floor jack.
16. On the engine side, there are 2 centering locations. Be sure that the transmission mounting bolt holes are aligned with them before mounting the transmission and transfer assembly to the engine. Lowering the rear of the engine SLIGHTLY may help align the 2 assemblies.
17. Install or connect the following:
    • Transmission assembly onto the engine making sure the aligning areas stay aligned. Torque the bolts to 54 ft. lbs. (75 Nm).
18. Lift the transmission/transfer assembly with the floor jack. Since the engine is now attached to the transmission, it also will rise slightly. Adjust its jack to keep only slight support.
19. Install or connect the following:
    • Crossmember in place and secure with the mounting bolts. Torque the bolts to 47 ft. lbs. (65 Nm).
    • Transmission and transfer case assembly onto the crossmember
    • Crossmember-to-transmission bolts. Torque the bolts to 15–18 ft. lbs. (20–24 Nm) on Montero sport and to 36 ft. lbs. (49 Nm) on Montero.
    • Mounting bracket back onto the transfer case, if equipped
    • Bell housing lower cover
    • Left-hand and right-hand side transmission stays
    • Starter motor and heat shield
    • Clutch release cylinder
    • Speedometer cable into the transmission and secure it there with the retaining ring.
    • Center differential lock detection switch connection
    • HI/LO detection switch connector
    • Back-up light switch connector
    • O2S sensor connector
    • Speed Sensor Connector
    • Pulse generator connector
    • 4WD indicator light switch connector
    • Ground cables
    • Flexplate-to-torque converter bolts. Torque the bolts to 25–30 ft. lbs. (35–42 Nm). On automatic transmissions
    • Dipstick tube
    • Shift linkage
    • Fluid cooler lines. Torque the line fittings to 32 ft. lbs. (44 Nm). On automatic transmissions
20. Tap the dust seal guard back onto the rear extension housing with a rubber or plastic mallet.
21. Install or connect the following:
    • Front driveshaft into the transfer case, then attach it to the front differential
    • Rear driveshaft, make certain that the matchmarks line up.
    • Front exhaust pipe to the catalytic converter and the exhaust manifolds
    • Transfer case protector, if equipped
    • Transmission and transfer case shift lever assembly. On manual transmissions
    • Negative battery cable to the battery
22. Refill the transmission and transfer case with oil.
23. Start the vehicle and check for any leaks.