:	Sep 27, 2007

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Disconnect the battery ground cable.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Remove the front driveshaft.

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Remove the exhaust system.

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Remove the rear driveshaft.

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Remove the starter motor.

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Release the selector cable.   Using an additional wrench, restrain the clamping bush and loosen the locknut.   Compress the latch and release the cable.

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: Always plug any open connections to prevent contamination. Disconnect the transmission fluid lines.   Remove the bolt.   Release the clip.   Remove and discard the 2 O-ring seals.

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Remove the turbocharger support bracket.   Remove the nut and 2 bolts.

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Remove the exhaust heat shield.   Remove the 7 nuts.

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Remove the exhaust cross-over pipe LH support bracket.   Remove the 3 bolts.   Release the transmission wiring harness.

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Remove the exhaust cross-over pipe RH support bracket.   Remove the 3 bolts.

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Remove the exhaust cross-over pipe center support bracket.   Remove the 2 bolts.

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Release the wiring harness from the LH side of the transmission.   Remove the 2 bolts.   Release the clip.

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Release the wiring harness from the RH side of the transmission.   Remove the bolt.   Disconnect the electrical connector.

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Disconnect the transfer case electrical connectors.   Disconnect the 3 electrical connectors.

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: Always plug any open connections to prevent contamination. :   Transmission shown removed for clarity. Disconnect the breather line.   Depress the locking ring.

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Release the wiring harness from the transfer case.   Remove the 3 bolts.   Release the clip.

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Remove the radiator access panel.   Remove the 4 bolts.

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Release the flexplate.   Remove the access plug.   Rotate the crankshaft in a clockwise direction to access the retaining bolts.   Remove the 4 bolts.

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Using a transmission jack, support the transmission.

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: Secure the transmission to the transmission jack.   : Support the engine. The engine will move forward when the transmission is removed.   : Make sure the torque converter remains connected to the transmission. :   Transmission shown removed for clarity. With assistance, remove the transmission.   Remove the 15 transmission bolts.

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Using a suitable tool, retain the torque converter.

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:   Do not disassemble further if the component is removed for access only. Remove the transmission from the transmission jack.

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Drain the transmission fluid.

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With assistance, remove the transfer case.   Remove the 8 bolts.   Remove and discard the O-ring seal.

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Remove the selector cable bracket.   Remove the bolts.

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Remove the selector lever.   Remove the nut.

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Release the fuel filter housing and support bracket.

: If the automatic transmission fluid is very dirty or it contains metallic particles, then along with a new transmission, install a new automatic transmission fluid cooler and lines.

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:   Clean the component mating faces. :   Install a new O-ring seal. With assistance, install the transfer case.   Lubricate input shaft splines with 'Weicon TL7391' grease.   Install the 8 bolts.   Using the special tool, tighten the bolts to 45 Nm (33 lb.ft).

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Secure the selector lever.   Tighten the nut to 12 Nm (9 lb.ft).

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Attach the selector cable bracket.   Install the 2 bolts and tighten to 10 Nm (7 lb.ft).

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Secure the wiring harness to the transmission.   Repeat the above procedure for the other side.   Tighten the bolt to 10 Nm (7 lb.ft).

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Using a suitable tool, retain the torque converter.

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Position the transmission to the transmission jack.

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Remove the torque converter retainer.

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:   Apply grease of the correct specification to the torque converter spigot. :   Clean the component mating faces. With assistance, install the transmission.   Tighten the 15 bolts to 45 Nm (33 lb.ft).

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Connect the breather line.

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Secure the wiring harness to the transmission.   Connect the electrical connector.   Tighten the screws.   Secure the wiring harness to the transmission.

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:   Clean the component mating faces. :   Install the new O-ring seals. Attach the transmission fluid lines.   Secure the transmission fluid lines to the clip.   Tighten the bolt to 10 Nm (7 lb.ft).

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Attach the flexplate to the torque converter.   Rotate the crankshaft to access the bolts.   Install the access plug.   Tighten the 4 bolts to 45 Nm (33 lb.ft).

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Install the starter motor.

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Install the radiator access panel.   Install the 4 bolts and tighten to 10 Nm (7 lb.ft).

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Secure the exhaust cross-over pipe center support bracket.   Tighten the bolts to 25 Nm (18 lb.ft).

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Install the exhaust cross-over pipe RH support bracket.   Align the exhaust cross-over pipe support bracket assembly.   Tighten the bolts to 25 Nm (18 lb.ft).

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Install the exhaust cross-over pipe LH support bracket.   Tighten the bolts to 25 Nm (18 lb.ft).   Attach the transmission wiring harness to the support bracket.

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Install the exhaust heat shield.

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Install the turbocharger support bracket.   Tighten the nut and 2 bolts to 22 Nm (16 lb.ft).

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Install the rear driveshaft.

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Install the front driveshaft.

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Install the exhaust system.

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:   Do not fully tighten the locking nut at this stage. Connect the selector cable to the transmission.   Engage the inner cable with the lever clamping bush.   Install the selector cable to its abutment bracket.

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Adjust the selector cable.

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Connect the battery ground cable.

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Check and top-up the transfer case fluid level.

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Check and top-up the transmission fluid level.

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Lower the vehicle.