A/T Installation

1.Install the air cleaner housing mounting bracket.

 

2.Install the front mount.

 

3.Install the rear mount/bracket.

NOTE: The illustration shows the 4WD model; 2WD model is similar.

 

4.Install the torque converter assembly (A) on the mainshaft (B) with the new O-ring (C).

 

5.Install the 14 x 20 mm dowel pins (D) in the torque converter housing.

6.Place the transmission on a jack, and raise the transmission to the engine level.

7.Attach the transmission to the engine, then install the transmission housin mounting bolts.

 

8.Install the stiffener (A).

9.Install the transmission housing mounting bolts.

 

10.Install the transmission housing mounting bolts.

 

11.Install the transmission mount bracket. Tighten the mount bolt (A) loosely, and tighten the transmission mount bracket bolt and nuts to the specified torque, then tighten the mount bolt to the specified torque.

 

12.Install the new set ring (A) on the intermediate shaft (B).

 

13.Clean the areas where the intermediate shaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Then install the intermediate shaft in the differential. While installing the intermediate shaft, be sure not to allow dust or other foreign particles to enter the transmission.

14.Install the intermediate shaft cover (C) with installing the mounting bolts loosely.

15.First tighten the right upper bolt (D) on the cover, then right lower bolt (E), and lastly the left bolt (F).

16.Install the new set ring (A) on the left driveshaft (B).

 

17.Install the right and left driveshaft.
While installing the left driveshaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission.

NOTE:
  • Clean the areas where the left driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air.
  • Turn the right and left steering knuckle fully outward, and slide the left driveshaft into the differential unitil you feel its set ring engages the side gear. Slide the right driveshaft over the intermediate shaft splines until you feel the driveshaht engages the intermediate shaft set ring.

18.Install the propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C).

 

19.Support the sub-frame (A) with a 4 x 4 x 40 in. piece of wood (B), and lift it up to body.

 

20.Loosely install the new sub-frame mounting bolts.

 

21.Align the reference marks (A) with the center of the sub-frame mounting bolts (B), then tighten the bolts to the specified torque.

 

22.Install the rear mount bolts.

 

23.Install the front mount bolt (A) and nut (B), connect the ATF cooler hose (C) to the ATF cooler line, then secure the hose with the clip.

 

24.Install the shift cable for 4WD model.

-1 Face the dot (A) on the shift cable (B) down, then install the shift cable bracket (C) on the shift cable.

-2 Attach the shift cable end (D) to the control lever (E), then insert the control pin (F) into the control lever hole through the shift cable end.

-3 Secure the control pin with the spring clip (G). Do not bend the shift cable excessively.

-4 Secure the shift cable bracket (H) with the bolts, and install the shift cable cover (I) with installing the mounting bolts loosely.

-5 First tighten the front bolt (J) on the cover, then lower bolt (K), and lastly the middle bolt (L).

 

25.Install the shift cable for 2WD model.

-1 Attach the shift cable end (A) to the control lever (B), then insert the control pin (C) into the control lever hole through the shift cable end, and secure the control pin with the spring clip (D). Do not bend the shift cable excessively.

-2 Secure the shift cable bracket (E) with the bolt, and install the shift cable cover (F) with installing the mounting bolts loosely.

-3 First tighten the front bolt (G) on the cover, then lower bolt (H), and lastly the middle bolt (I).

 

26.Attach the torque converter to the drive plate with eight bolt (A). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates freely.

 

27.Install the torque converter cover (B).

28.Connect the ball joints (A) to the lower arms (B), and install the castle nuts (C) and spring clips (D).
Install the spring clips from the inside of the vehicle, and its hooked side facing the front (E) of the vehicle in the range of the insertion direction shown.

 

29.Connect the ball joints (F) to the lower arms, and install the nuts (G). Insert a 5 mm Allen wrench (H) in the top of the ball joint pins, and tighten the nuts.

30.Connect the ATF cooler hoses (A) to the ATF cooler lines (B).

 

31.Connect the shift solenoid harness connector (A), A/T clutch pressure control solenoid valve B connector, and solenoid valve C connector. Install the harness clamps (D) on the clamp brackets (E).

 

32.Connect the 3rd clutch pressure switch connector.

 

33.Install the splash shield.

34.Remove the hoist from the hoisting bracket (A), and remove the hoisting bracket and collar (B) (if installed) from the engine.

 

35.Install the water pipe bolts (C), and tighten the air cleaner housing mounting bracket bolt(D). Install harness cover (E).

36.Connect the transmission range switch connector (A), and install it on its bracket (B).

 

37.Connect the connectors to the mainshaft speed sensor (C) and countershaft speed sensor (D).

38.Connect the A/T clutch pressure control solenoid valve A connector and 2nd clutch pressure switch connector (B), and install the harness clamps (C) on the clamp brackets (D).

 

39.Install the transmission ground terminal (E).

40.Install the battery base, then install the harness clamp on the clamp bracket on the base.

41.Refill the transmission with ATF.

42.Install the intake air duct and air cleaner housing.

43.Install the battery tray and battery, then secure the battery with its hold-down bracket.

44.Connect the battery positive terminal, then connect the negative terminal.

45.Set the parking brake. Start the engine, and shift the transmission through all gears three times.

46.Check the shift lever operation, A/T gear position indicator operation, and shift cable adjustment.

47.Check and adjust the front wheel alignment.

48.Start the engine and let it idle reach normal operating temperature (the radiator fan comes on) with the transmission in [P] or [N] position, then turn if off and check the ATF level.

49.Perform the road test.

50.Loosen the bolts of the front,rear and transmission mounts after the road test.

51.Retighten the transmission mount bolt.

NOTE: Be sure to tighten the mount bolts following sequence.

Torque: 54 N·m (5.5 kgf·m, 40 lbf·ft) 

52.Retighten the rear mount bolt.

Torque: 64 N·m (6.5 kgf·m, 47 lbf·ft) 

53.Retighten the front mount bolt.

Torque: 64 N·m (6.5 kgf·m, 47 lbf·ft)