Removal and Installation
WITH AUTOMATIC TRANSMISSION1. Raise and support vehicle.
2. Support engine and transmission with a suitable jack or jack stand.
3. Disconnect catalytic converter support bracket from adapter housing.
4. Remove skid plate.
5. Disconnect speedometer cable and adapter from transfer case. Discard adapter O-ring.
6. Mark propeller shafts and transfer case yoke for assembly reference. Then, disconnect propeller shafts from yokes. Secure shafts aside.
7. Disconnect gearshift and throttle linkage from transmission.
8. Remove rear crossmember.
9. Remove transfer case to adapter housing nuts.
10. Remove transfer case from vehicle.
11. Install transfer case on adapter housing.
12. Install and torque transfer case to adapter housing nuts to 33 ft. lbs.
13. Install rear crossmember.
14. Install rear brace rod.
15. Remove jack or jack stand, supporting engine and transmission.
16. Connect gearshift and throttle linkage to transmission.
17. Connect propeller shafts to transfer case yokes.
18. Install new O-ring on speedometer adapter, then the adapter and speedometer cable to transfer case.
19. Install skid plate.
20. Connect catalytic converter support bracket to adapter housing.
21. Check transfer case lubricant level and adjust, if necessary. Also, check transmission linkage adjustments.
WITH MANUAL TRANSMISSION
1. Shift transmission into neutral.
2. Remove screws attaching gear shift lever bezel to floorpan or console (if equipped).
3. Slide bezel and boot up on gear shift lever to gain access to lever attaching bolts, then remove bolts and remove lever.
4. Remove bolts attaching gear shift lever mounting cover to transmission adapter housing and remove cover.
5. Remove nut from transfer case mounting stud from inside transmission adapter housing.
6. Raise and support vehicle.
7. Remove skid plate and stiffening brace, or rear brace rod.
8. Remove speedometer adapter retainer attaching bolt and remove retainer, adapter and cable, then plug adapter opening in transfer case to avoid excessive oil leakage. Before removing speedometer adapter, mark position for reference during assembly.
9. Mark propeller shafts and axle yokes for assembly reference and disconnect propeller shafts at transfer case.
10. Remove transfer case shift motor vacuum harness.
11. Support transfer case with transmission jack, then remove nuts from transfer case mounting studs and remove transfer case.
12. Align transmission output and transfer case input shafts and install transfer case on transmission adapter housing, then install and torque transfer case mounting stud nuts to 33 ft. lbs.
13. Remove jack supporting transfer case.
14. Connect propeller shafts to axle yokes and torque clamp strap bolts to 15 ft. lbs.
15. Install new O-ring on speedometer adapter, then install adapter and cable and retainer, torque retainer bolt to 100 inch lbs.
16. Install skid plate and stiffening brace, or rear brace rod and torque retaining bolts to 30 ft. lbs.
17. Install transfer case shift motor vacuum harness.
18. Check and correct fluid levels in transmission and transfer case, then lower vehicle.
19. Install nut on transfer case mounting stud inside transmission adapter housing, torque nut to 33 ft. lbs.
20. Install gear shift lever mounting cover on transmission adapter housing, then install gear shift lever on mounting cover.
21. Position gear shift lever boot and bezel on floorpan of console (if equipped), and install bezel attaching screws. Steps 1 through 5 and 19 through 21 apply to SR-4 transmission only.