4WD

1. INSTALL TRANSFER AND PROPELLER SHAFT UPPER DUST COVER TO TRANSMISSION WITH NEW GASKET





- Shift the two shift fork shafts to the high-four position.





- Apply MP grease to the adaptor oil seal.
- Place a new gasket to the transfer adaptor.
- Install the transfer to the transmission.

NOTE: Take care not to damage the oil seal by the input gear spline when installing the transfer.





- Install and torque the bolts with the propeller shaft upper dust cover.

Torque: 400 kg.cm (29 ft.lb, 39 N.m)

- Install the dust cover bolt to the bracket.

NOTE: There are two bolt lengths, 43 mm (used for the dust cover) and 39 mm.





2. INSTALL ENGINE REAR MOUNTING

Torque: 260 kg.cm (19 ft-lb, 25 N.m)

3. PLACE TRANSMISSION WITH TRANSFER AT INSTALLATION POSITION
- Support the transmission with a jack.
- Align the input shaft spline with the clutch disc, and push the transmission with the transfer fully into position.





4. INSTALL TRANSMISSION BOLTS AND STIFFENER BOLTS

Torque:
Transmission mounting bolt: 730 kg.cm ( 53 ft-lb, 72 N.m)
Stiffener plate bolt: 380 kg.cm ( 27 ft-lb, 37 N.m)





5. INSTALL NO.2 FRAME CROSSMEMBER
- Raise the transmission slightly with a jack.
- Install the No.2 frame crossmember to the side frame with the bolts. Torque the bolts.

Torque: 970 kg.cm (70 ft-lb, 95 N.m)

- Lower the transmission and transfer.
- Install the four mounting bolts to the engine rear mounting.
- Torque the bolts.

Torque: 130 kg.cm (9 ft.lb, 13 N.m)

6. REMOVE PIECE OF WOOD FROM FRONT AXLE
7. (R151F)
CONNECT STABILIZER BAR TO SIDE FRAME

Torque: 130 kg.cm (9 ft-lb, 13 N.m)





8. INSTALL EXHAUST PIPE, BRACKET AND CLAMP
- Install the exhaust pipe to the manifold.

Torque: 630 kg-cm (46 ft-lb, 62 N.m)

- Install the pipe bracket to the clutch housing.
- Torque the bolts.

Torque:
Upper: 380 kg.cm (27 ft-lb, 37 N.m)
Lower 700 kg.cm (51 ft-lb, 69 N.m)

- Install the exhaust pipe clamp.





9. INSTALL STARTER LOWER MOUNTING BOLT AND RELEASE CYLINDER TUBE BRACKET
10. INSTALL CLUTCH RELEASE CYLINDER

Torque: 120 kg.cm (9 ft-lb, 12 N.m)

11. CONNECT SPEEDOMETER CABLE, BACK-UP LIGHT SWITCH CONNECTOR AND TRANSFER INDICATOR SWITCH CONNECTOR
12. CONNECT PROPELLER SHAFT
13. FILL TRANSMISSION AND TRANSFER WITH OIL

Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90 or 80W-90
Capacity:
Transmission:
W56, R151F 3.0 liters (3.2 US qts, 2.6 Imp. qts)
G52 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Transfer 1.6 liters (1.7 US qts, 1.4 Imp. qts)

14. LOWER VEHICLE
15. INSTALL STARTER UPPER MOUNTING NUT





16. INSTALL TRANSFER SHIFT LEVER

- Apply MP grease to the transfer shift lever.
- Using pliers, install the shift lever.





17. INSTALL TRANSMISSION SHIFT LEVER
- Apply MP grease to the transmission shift lever.
- (G52,R151F)
Using SST, install the shift lever and install the shift lever boot in place.

SST 09305-20012

- (W56)
Install the shift lever with four bolts, and install the shift lever boot and retainer with six screws.

Torque: 130 kg.cm (9 ft-lb, 13 N.m)

18. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL
19. PERFORM ROAD TEST
- Check for abnormal noise and smooth operation.