Remove and Refit

REMOVE
1. Place the vehicle on a hydraulic hoist and chock the road wheels.
2. Disconnect the battery negative terminal.
3. Release and remove the fan blade assembly. Note the assembly has a left hand thread.
4. Release the clamp and remove the air intake hose from the neck of the plenum chamber.
5. Disconnect the kickdown cable from the throttle linkage.
6. Release the two transmission breather pipes from the clip located on the lifting eye at the rear of the right hand cylinder head.
7. Remove the transmission dipstick.





8. Select low range, unscrew and remove the transfer case knob.
9. Unclip the top cover of the main transmission selector and remove the circlip, withdraw the detent button. Remove the circlip above the selector knob retention nut, remove the nut, serrated washer and withdraw the selector knob.
10. Carefully pry the inset panel out of the floor mounted console, complete with gear selector illumination panel and ashtray. Disconnect the electrical multi - plug to the graphics panel, and remove the inset panel.
11. Release the four screws and remove the glove box liner.
12. Carefully pry the window lift switch panel from the front of the glove box. Push the panel complete with switches back through the panel opening and place on the transmission tunnel.





13. Release the two bolts and two screws securing the glove box/console assembly to the transmission tunnel.
14. Detach the two relays from the inner side of the glove box.
15. Disconnect the electrical leads to the rear cigar lighter.
16. Disconnect the parkbrake cable from the parkbrake lever. Raise the lever while simultaneously detaching the glove box/console assembly from the lower dash. Remove the assembly from the vehicle.
17. Remove the retaining clip and pull the parkbrake adjustment thumb wheel from the outer sleeve. Push the inner sleeve to the underside of the vehicle.
18. Remove the sound deadening trim from the top of the transmission tunnel.
19. Remove the screws and detach the retaining plate from around the transfer case lever.
20. Raise the hydraulic ramp.








21. Remove the transmission and transfer case oil drain plugs. Where applicable remove the filler plug to assist draining and drain the oil into suitable containers. While the oil is draining continue with the following operations.
22. Disconnect the multi-plugs to the Lambda sensors.
23. Remove the front exhaust down pipes and intermediate pipe complete with center muffler.

NOTE: The above operation will require the assistance of a second mechanic to support the exhaust system while the various fasteners are released.

24. Remove the eight bolts securing the cross member. Note it may be necessary to spread the chassis to enable the cross member to be withdrawn.
25. Release the two clamps at the side of the engine pan that secure the two transmission oil cooler feed and return pipes.
26. Place a suitable container below the transmission, disconnect the oil cooler feed and return pipes from the bottom and side of the transmission. Plug the pipes and openings to prevent ingress of foreign matter.





27. Disconnect the dipstick tube from the front of the transmission oil pan.
28. Mark each drive shaft flange at the transfer case with an identification line to aid re-assembly Remove the fasteners and disconnect the propeller shafts at the output flanges. Tie the shafts to one side.
29. Release the nut and disconnect the speedometer cable from the rear output housing, tie the cable to one side.
30. Disconnect the main transmission selector cable and rod from the left side of the transmission. Lay the cable aside.
31. Disconnect the main transmission inhibitor switch multi-plug from the main harness.
32. If fitted disconnect the speed transducer multi-plug from the main harness.
33. Remove the nine front cover plate bolts from the bottom of the transmission bellhousing. Detach the cover plate to gain access to the four torque converter fixing bolts.





34. Rotate the engine using the crankshaft pulley until two of the access holes in the drive plate/ring gear assembly are visible through the bell housing bottom cover opening.
35. Remove the two bolts that are visible through the access holes, which secure the drive plate to the torque converter. Mark one of the access holes and a bolt hole in the converter with an identification line to aid re-assembly and to maintain original build setting.
36. Rotate the crankshaft 180 until the remaining access holes are visible. Remove the remaining two bolts.
37. Position a suitable transmission floor jack on the rear output housing or brake drum to support the weight of the transmission assembly.
38. Remove the bolts and withdraw the transfer case mountings.
39. Fit the previously manufactured fixture on a transmission hoist, raise the hoist and position the fixture and hoist under the transfer case mounting points.
40. Using the original transmission mounting bolts secure the fixture to the transmission.
41. Remove the transmission floor jack from the rear of the transfer case.
42. Carefully lower the transmission until the top of the transfer case clears the rear passenger footwell.
43. Position the transmission floor jack under the engine to support the weight while the bellhousing bolts are removed.
44. Remove the bellhousing bolts noting that one of the bolts also secures the transmission dipstick tube.
45. Withdraw the transmission assembly from the engine, ensuring that the torque convertor is removed with the transmission and does not stay on engine.

REFIT
1. Refitting the transmission is a reversal of the removal procedure noting the following points.
2. The flexible drive plate to torque converter bolts are to be coated with Loctite(r) 270, or equivalent, prior to assembly.
3. Tighten all fasteners to 52 Nm (29-37 ft lb).
4. New gaskets are to be fitted to the exhaust flanges; all joints other than those fitted with doughnuts, to be coated with exhaust sealer. Check the system, if any leaks are evident reseal as necessary.