Connection of Each Section

1. Install oil pipe.





2. Install the reduction driven gear.
3. Install the parking pawl and shaft.
4. Set the select lever in the "P" range and tighten the drive pinion lock nut.
Tightening Torque: 98 +/-5 Nm (72.3 +/-3.6 ft. lbs.).

NOTE: After tightening, stake the lock nut securely.





5. Install the reduction drive gear assembly.

CAUTION: Align mark on reduction drive gear with mark on driven gear during installation.

NOTE: Insert it fully into position until the bearing shoulder bottoms.





6. Measurement and adjustment of extension end play.
a. Measure distance L from end of extension case and rear drive shaft with Special Tool (ST).
ST 398643600 Gauge or equivalent.
L = Measured value-15





b. Measure the distance e from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
l = Measured value-50
ST1 398643600 Gauge or equivalent.
ST2 499577000 Gauge or equivalent.
c. Calculation equation: T = (L+0.4)-h
C: Clearance between end of reduction drive gear and end of rear drive shaft.
L: Distance from end of extension case to end of rear drive shaft. (Distance from end of case to point at bearing location)
0.4: Gasket thickness
l: Height from end of transmission case to end of reduction drive gear.
Select suitable thrust needle bearing from among those listed in the following table to adjust clearance in the 0.05 - 0.20 mm (0.0020 - 0.0079 inch) range.





Select from one to five shims so that clearance is within specifications.





7. Installation of extension case and transmission case.
a. Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.
b. Set the parking return spring.
c. Remove the transfer clutch from the extension case.
Set the needle bearing on the reduction drive shaft and then install transfer clutch to the transfer clutch hub.

NOTE: Be sure to engage the spline teeth correctly.

d. With gasket inserted between them, install the extension case to the transmission case.
Tightening Torque: 25 +/-2 Nm (18.1 +/-1.4 ft. lbs.).

CAUTION:
- Be sure to use a new gasket.
- After inserting the extension case halfway, connect the connector for duty solenoid C. Be careful not to jam the cord in the case.
- Be careful not to damage the rear drive shaft seal ring.

e. Tighten bolts to secure the case.