Removal and Replacement
Manual Transmission Assembly Dismounting and RemountingDismounting
1) Disconnect negative (-) cable of battery.
2) Remove transmission shift control lever.
3) Detach engine harness clamps and ground wire harness from transmission front case.
4) Remove starting motor fastening bolts (2) and transmission fastening bolts (1).
5) Disconnect clutch fluid joint from pipe of clutch operating cylinder assembly.
6) Hoist vehicle.
7) Drain oil from transmission and transfer or extension case.
8) Remove propeller shafts.
9) Remove exhaust No.2 pipe.
10) Remove engine under cover.
11) Remove clutch housing lower plates (1).
12) Remove transmission fastening nut (2) and bolts (3).
13) Disconnect the following couplers and release their harness from clamps.
^ Back up light switch e Transfer shift actuator (if equipped)
^ 4L/N switch (if equipped)
^ Center differential lock switch (if equipped)
14) Apply transmission jack (1) and remove engine rear mounting member (2) taking off its bolts.
15) After removing mounting member, move rearward transmission and transfer or extension case assemblies placed on jack and then lower them.
16) Separate gear shift control lever rear case assembly (2) and transfer assembly (3) or extension case from transmission assembly (1).
Remounting
For remounting, reverse dismounting procedure.
^ Apply grease to input shaft.
"A":Grease 99000-25010 (SUZUKI Super Grease A)
^ Slant the rear of the engine down, using support device (1) and install transmission to engine.
^ Use specified torques as given below.
Tightening torque
Transmission to engine bolt and nut (a): 85 Nm (8.5 kg-m, 61.5 ft. lb.)
Engine rear mounting member bolt (b): 55 Nm (5.5 kg-m, 40.0 ft. lb.)
Clutch housing lower plate bolt (c): 11 Nm (1.1 kg-m, 8.0 ft. lb.)
Engine rear mounting No.2 bolt (d): 55 Nm (5.5 kg-m, 40.0 ft. lb.)
^ Set each clamp for wiring and hose securely.
^ Install shift control lever.
^ Connect clutch fluid joint to pipe of clutch operating cylinder assembly.
^ Install exhaust No.2 pipe.
^ Fill gear oil to transmission.
^ Fill gear oil to transfer or extension case.
^ Connect battery and check function of engine, clutch, transmission and transfer.
^ Install propeller shafts.
