Assembly

EXTENSION ASSEMBLY
1. Installation of ball bearing (1) and selection of snap ring (2) (Inner-72).
a. Attach ball bearing (1) (30 x 72 x 17) to extension and install snap ring (2).





b. Measure clearance between snap ring (2) and outer race of ball bearing (1) with a thickness gauge.

CAUTION: Replace ball bearing with a new one.

Clearance: 0 - 0.15 mm (0 - 0.0059 inch)





c. If the measurement is not within the specification, select suitable snap ring (2).





2. Installation of transfer drive gear (3). Press transfer drive gear into inner race of ball bearing.





3. Selection of snap ring (4) (Outer-30)
a. Install snap ring (4) on transfer drive shaft.
b. Measure clearance between snap ring and inner race of ball bearing with a thickness gauge.

Clearance: 0 - 0.15 mm (0 - 0.0059 inch)





c. If the measurement is not within the specification, select suitable snap ring.





4. Install extension cover (6), gasket (5) and shift bracket (7).

CAUTION: Use new gasket.

5. Install oil seal (8) with ST.

ST 498057300 Installer, or equivalent.

CAUTION: Use new oil seal.

TRANSFER CASE ASSEMBLY

NOTE: Assembly of transfer case is in the reverse order of disassembly.

1. Assembly of reverse check sleeve.





a. Install reverse accent shaft (F), check cam (D), return spring (E) and check spring (C) onto reverse check sleeve.

NOTE: Be sure the bent section of reverse check spring is positioned in the groove in check cam.

b. Hook the bent section of reverse check spring over reverse check plate (B).
c. Rotate cam so that the protrusion of reverse check cam is at the opening in plate.
d. With cam held in that position, install plate onto reverse check sleeve and hold with snap ring (A) (Inner-28).
e. Position O-ring (G) (35.4 x 1.5) in groove in sleeve.





CAUTION:
^ Make sure the cutout section of reverse accent shaft is aligned with the opening in reverse check sleeve.
^ Spin cam by hand for smooth rotation. If it does not return properly, replace reverse check spring.
^ Move cam and shaft all the way toward plate and release. If cam does not return properly, replace reverse check spring; if shaft does not, check for scratches on the inner surface of sleeve. If sleeve is in good order, replace spring.
^ Select a suitable reverse accent shaft and reverse check plate by referring to NEUTRAL POSITION ADJUSTMENT.





2. Installation of shifter arm (7) and selector arm (8) Install shifter arm into the partition from the front while inserting selector arm into the opening in reverse check sleeve. Pass shaft through hole in selector arm until its end comes out of the rear of transfer case.

NOTE: Apply a coat of gear oil to shifter arm. Also make sure oil seal is positioned properly.

Tightening torque:
T1: 6.4 +/- 0.5 Nm (56.4 +/- 4.8 inch lbs.).
T2: 10 +/- 1 Nm (86.4 +/- 8.4 inch lbs.).
T3: 19.6 +/- 1.5 Nm (14.5 +/- 1.1 ft. lbs.).
T4: 25 +/- 2 Nm (18.1 +/- 1.4 ft. lbs.).





COMBINATION OF TRANSFER CASE AND EXTENSION ASSEMBLY
1. Install center differential (1) and transfer driven gear (2) into transfer case.

Tightening torque:
T: 37 +/- 3 Nm (27.5 +/- 2.2 ft. lbs.).





2. Selection of thrust washer (52 x 61 x t)
a. Measure height "W" between transfer case and ball bearing on the transfer driven gear (3).





b. Measure depth "X" as shown. (4) Extension
c. Calculate space "Y" using the following equation: Y = X - W + 0.24 mm (0.0094 inch) [Thickness of gasket]





d. Select suitable washer in the table:

Standard clearance between thrust washer and ball bearing: 0.05 - 0.30 mm (0.0020 - 0.0118 inch)

e. Fit thrust washers on transfer drive shaft.





3. Install extension assembly into transfer case.