Part 3

REAR EXTENSION HOUSING





Components

Disassembly





1. REMOVE OIL PUMP DRIVE SHAFT





2. REMOVE OIL PUMP COVER
a. Using a torx socket wrench (T30), remove the 3 screws.
b. Install the 2 suitable bolts to the pump cover.
c. Remove the pump cover from the rear extension housing.





3. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR





4. REMOVE DRIVEN ROTOR FROM REAR EXTENSION HOUSING





5. REMOVE SCREW PLUG, SPRING, BALL AND VALVE SEAT
a. Using a hexagon wrench, remove the screw plug.
b. Using a magnetic finger, remove the spring, ball and valve seat from the rear extension housing.





6. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY
a. Using a snap ring expander, remove the snap ring.
b. Remove the coupling assembly from the rear extension housing.





7. REMOVE SEPARATOR AND OIL PUMP PLATE
Remove the 3 bolts, separator and oil pump plate.
8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
a. Using a snap ring expander, remove the snap ring.
b. Remove the vehicle speed sensor drive gear.
9. REMOVE REAR OUTPUT SHAFT
a. Using a snap ring expander, remove the snap ring.





b. Using SST and a hammer, remove the rear output shaft. SST 09325-12010
c. Remove the 2 seal rings from the rear output shaft.
10. REMOVE DUST DEFLECTOR
a. Using a screwdriver and hammer, remove the rear extension housing dust deflector.
b. Using a screwdriver and hammer, remove the rear output shaft dust deflector.
11. REMOVE OIL SEAL





Using a screwdriver, pry out the oil seal from the rear extension housing.





12. REMOVE BALL BEARING
a. Using a screwdriver, remove the snap ring.
b. Using SST and a press, remove the ball bearing from the rear extension housing.
SST 09316-60011 (09316-00011, 09316-00021)

Inspection
1. INSPECT DRIVEN ROTOR BODY CLEARANCE
a. Install the drive rotor to the driven rotor.





b. Using a feeler gauge, measure the body clearance between the drive rotor and extension housing.

Standard clearance:
0.08 - 0.17 mm (0.0031 - 0.0067 inch)
Maximum clearance:
0.17 mm (0.0067 inch)

If the body clearance exceeds the maximum, replace the drive rotor and driven rotor.





2. INSPECT DRIVEN ROTOR TIP CLEARANCE
Using a feeler gauge, measure the tip clearance between the drive rotor and driven rotor.

Standard clearance:
0.05 - 0.15 mm (0.0020 - 0.0059 inch)
Maximum clearance:
0.15 mm (0.0059 inch)

If the tip clearance exceeds the maximum, replace the drive rotor and driven rotor.





3. INSPECT OIL PUMP SIDE CLEARANCE
Using a steel straight edge and feeler gauge, measure the side clearance of oil pump.

Standard clearance:
0.03 - 0.10 mm (0.0012 - 0.0039 inch)
Maximum clearance:
0.10 mm (0.0039 inch)

If the side clearance exceeds the maximum, replace the drive rotor and driven rotor.

Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL BALL BEARING





a. Using SST and a press, install the ball bearing.
SST 09316-60011 (09316-00011, 09316-00031)





b. Select a snap ring that will allow the minimum axial play.





c. Using a screwdriver, install a new snap ring.
2. INSTALL DUST DEFLECTOR





a. Using SST and a hammer, install a new rear extension housing dust deflector.
SST 09316-60011 (09316-00011, 09316-00041)





b. Using SST and a press, install a new rear output shaft dust deflector.
SST 09316-20011, 09316-60011 (09316-00011)
3. INSTALL OIL SEAL
a. Apply MP grease to the lip of a new oil seal.





b. Using SST and a hammer, drive in a new oil seal.
SST 09316-60011 (09316-00011, 09316-00031)





4. INSTALL REAR OUTPUT SHAFT
a. Using SST and a press, install the rear output shaft.
SST 09316-20011,09316-60011(09316-00011,09316-00031)
b. Install the 2 seal rings to the rear output shaft.





c. Select a snap ring that will allow the minimum axial play.





d. Using a snap ring expander, install a new snap ring.
5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
a. Install the vehicle speed sensor drive gear.
b. Using a snap ring expander, install the snap ring.





6. INSTALL OIL PUMP PLATE AND SEPARATOR
a. Install the oil pump plate.
b. Install the separator.
c. Install and torque the 3 bolts.

Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





7. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY
a. Install the coupling assembly to the output shaft.
b. Using a snap ring expander, install the snap ring.





8. INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG
a. Apply gear oil to the ball.
b. Install the valve seat, ball and spring.
c. Apply liquid sealer to the screw plug threads.

Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent

d. Using a hexagon wrench, install and torque the screw plug.

Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

9. INSTALL DRIVEN ROTOR
a. Apply gear oil to the driven rotor.
b. Install the driven rotor.





10. INSTALL DRIVE ROTOR
a. Apply gear oil to the drive rotor.
b. Install the drive rotor.

HINT: Align the alignment marks.





11. INSTALL OIL PUMP COVER
a. Install the oil pump cover.
b. Using a torx socket wrench (T30), install and torque the 3 screws.

Torque: 4.9 Nm (50 kgf-cm, 43 inch-lbs.)

NOTICE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.

12. INSTALL OIL PUMP DRIVE SHAFT