Extension Case

A: REMOVAL





1) Remove rear vehicle speed sensor.





2) Separate transmission case and extension case sections.

B: INSTALLATION
1) Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.

NOTE: Install thrust needle bearing in the correct direction.

2) Install the extension case to the transmission case.





3) Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)





4) Install the rear vehicle speed sensor.
Tightening torque: 7 Nm 0.7 kgf-cm, 5.1 ft. lbs.)

C: DISASSEMBLY
1. WITHOUT VTD
1) Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

CAUTION: Be careful not to damage the oil seal in the extension.





2) Remove the transfer pipe.

CAUTION: Be careful not to bend the pipe.





3) Remove the dust cover from the extension case.
4) Remove the oil seal from the extension case.

2. WITH VTD





1) Using ST1, ST2, ST3 and a press, remove snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS





2) Remove test plug.





3) Remove clutch piston by compressed air.
4) Remove transfer clutch pipe.

CAUTION: Be careful not to bend the pipe.





5) Remove the dust cover from the extension case.
6) Remove the oil seal from the extension case.

D: ASSEMBLY
1. WITHOUT VTD





1) Using the ST and a press, press in a new oil seal.
ST 498057300 INSTALLER
2) Press in the dust cover.
3) Install the transfer pipe to extension case.

CAUTION: Be careful not to bend the pipe.





4) Install the transfer clutch assembly to the case.

CAUTION: Be careful not to damage the seal rings.

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

2. WITH VTD
1) Using the ST and a press, press in a new oil seal.
ST 498057300 INSTALLER
2) Press in the dust cover.





3) Install transfer clutch pipe.

CAUTION: Be careful not to bend the pipe.





4) Install test plug.
Tightening torque: 13 Nm (1.3 kgf-cm, 9.4 ft. lbs.)





5) Insert the multiple clutch, the drive plate, the driven plate, and the spring retainer.
6) Using the ST1, ST2, and ST3, install the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS





E: INSPECTION
^ Use forced air to make sure the transfer pipe and extension case routes are not clogged and do not leak.
^ Measure the extension endplay and adjust it to within specifications. Refer to Transfer Clutch.