AUTOMATIC TRANSMISSION ASSEMBLY INSTALLATION


  1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY


    1. Inspect the torque converter clutch assembly Click here.

  2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

    A01J5ZBE01

    1. Install the torque converter clutch to the automatic transmission.

    2. Using a vernier caliper and straightedge, measure dimension A between the transmission and the end surface of the drive plate.

      Standard dimension
      A = 22.28 mm (0.8772 in.)
    3. A01J4FDE01

      Using a vernier caliper and straightedge, measure dimension B shown in the illustration. Check that B is greater than A.

      Standard dimension
      B = A + 1.00 mm (0.0394 in.) or more

  3. INSTALL TRANSFER ASSEMBLY


    1. Install the transfer to the transmission.

    2. Install the 2 clamps and 8 bolts.

      Torque:
      24 N*m  { 244 kgf*cm, 17 ft.*lbf }

  4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

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    1. Install the transmission to the engine with the 9 bolts.

      Torque:
      71 N*m  { 720 kgf*cm, 53 ft.*lbf, for bolt A }
      37 N*m  { 380 kgf*cm, 27 ft.*lbf, for bolt B }
    2. A01J7P2

      Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch mounting bolts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips

      First install the black bolt, and then the other 5 bolts.

  5. INSTALL FLYWHEEL HOUSING SIDE COVER

  6. INSTALL STARTER ASSEMBLY


    1. Install starter assembly Click here.

  7. CONNECT WIRE HARNESS

  8. CONNECT CONNECTOR


    1. Transmission side:

      Connect the connectors.


      1. Connect the park/neutral position switch connector.

      2. Connect the transmission wire connector.

      3. Connect the 2 speed sensor connectors.

    2. Transfer side:

      Connect the connectors.


      1. Connect the No. 1 indicator switch connector.

      2. Connect the No. 2 indicator switch connector.

      3. Connect the speed sensor connector.

  9. INSTALL NO. 1 ENGINE MOUNTING INSULATOR REAR

    A01J5DKE01

    1. Install the engine mounting insulator to the transmission with the 4 bolts.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  10. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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    1. *1: Install the 4 set bolts of the engine mounting insulator.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

    2. *2: Install the frame crossmember with the 4 bolts and 4 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  11. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

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    1. Install the control cable bracket with the 2 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  12. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

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    1. Connect the control cable with the clip.

    2. Connect the control cable with the nut.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  13. INSTALL OIL COOLER TUBE

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    1. Loosely install the tip of the oil cooler tube inlet to the automatic transmission by hand.

    2. Loosely install the tip of the oil cooler tube outlet to the automatic transmission by hand.

    3. Install the 2 clamps with the 2 bolts.

      Torque:
      5.0 N*m  { 50 kgf*cm, 43 in.*lbf }
    4. A01J33CE01

      Using a union nut wrench, tighten the oil cooler inlet and outlet tubes.

      Torque:
      34 N*m  { 346 kgf*cm, 25 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01J3V3E02

      Set a new gasket to the RH cylinder head with the oval shape facing forward.

      Note

      Be careful of the installation direction.

    2. Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Connect the A/F sensor connector.

  15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01J3GEE01

      Set a new gasket to the LH cylinder head with the oval shape facing backward.

      Note

      Be careful of the installation direction.

    2. Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Connect the A/F sensor connector.

  16. INSTALL NO. 2 MANIFOLD STAY

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    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  17. INSTALL MANIFOLD STAY

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    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  18. INSTALL REAR PROPELLER SHAFT ASSEMBLY


    1. Install the rear propeller shaft Click here.

  19. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  20. INSTALL EXHAUST PIPE


    1. Install the exhaust pipe Click here.

  21. CONNECT HEATED OXYGEN SENSOR

  22. INSTALL TRANSFER CASE LOWER PROTECTOR


    1. Install the protector with the 4 bolts.

      Torque:
      18 N*m  { 283 kgf*cm, 13 ft.*lbf }

  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  24. INSTALL TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY


    1. A01J42PE02

      While pushing the select return spring to the left with the end of the transfer high and low shift lever, insert the end of the shift lever into the shift fork.

    2. A01J3H4

      While holding down the shift lever cap, install the snap ring to install the transfer high and low shift lever.

    3. Return the transfer front drive shift boot to its original position.

  25. INSTALL SHIFT LEVER BOOT ASSEMBLY


    1. Install the shift lever boot with the 4 screws.

  26. INSTALL CONSOLE BOX ASSEMBLY

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    Text in Illustration
    *1 Screw
    *2 Bolt
    *3 Clip

    1. Install the console box with the 4 screws and 2 bolts.

    2. Install the 2 clips.

  27. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY


    1. Attach the 12 claws to install the upper console panel.

      A01J6F0E01
      Text in Illustration
      *A for 2WD *B for 4WD

  28. INSTALL PARKING BRAKE HOLE COVER SUB-ASSEMBLY


    1. Attach the 4 claws to install the parking brake hole cover.

  29. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY

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    1. Install the shift lever knob and twist it in the direction indicated by the arrow.

  30. ADD TRANSFER OIL


    1. Remove the case plug (for filler) and gasket.

    2. Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the case plug (for filler) hole.

      Note


      • When adding oil, pour it slowly.

      • Add oil a little at a time, waiting several minutes between each addition of oil.

    3. Wait approximately 5 minutes and check that the oil level has not changed.

    4. Install a new gasket and the case plug (for filler).

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  31. ADD AUTOMATIC TRANSMISSION FLUID


    1. Add automatic transmission fluid Click here.

  32. ADJUST AUTOMATIC TRANSMISSION FLUID


    1. Adjust the automatic transmission fluid Click here.

  33. INSPECT SHIFT LEVER POSITION


    1. Inspect the shift lever position Click here.

  34. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

  35. CHECK FOR EXHAUST GAS LEAKS

  36. INSTALL NO. 2 ENGINE UNDER COVER

    Torque:
    28 N*m  { 285 kgf*cm, 21 ft.*lbf }

  37. INSTALL NO. 1 ENGINE UNDER COVER

    Torque:
    28 N*m  { 285 kgf*cm, 21 ft.*lbf }