Extension Case

REMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Prepare the transmission for overhaul.





3. Remove the extension case.
4. Completely remove the remaining liquid gasket from the extension case and transmission case.

INSTALLATION
1. Select the transfer driven gear thrust washer, and then install it to extension case.
2. Apply oil lightly to the outer periphery of bearing cone, and then install it to extension case.
3. Select the thrust washer of transfer drive gear, and then install it to center differential.
4. Apply liquid gasket to the transmission case.





Liquid gasket: THREE BOND 1215 (Part No. 004403007)





5. Install the extension case.
Tightening torque: 48 Nm (4.9 kgf-cm, 35.4 ft. lbs.)





NOTE: Insert the stopper portion of center differential between extension guides.

6. Install the manual transmission assembly to vehicle.

DISASSEMBLY
1. Remove the transfer drive gear.





2. Remove the extension guide.





3. Remove the shift bracket.





4. Using the ST, remove the bearing cone.
ST 18758AA000 PULLER





5. Remove the thrust washer and oil plate.





6. Remove the shifter arm oil seal.
7. Remove the reverse checking system.
8. Remove the extension oil seal.

ASSEMBLY
1. Install the reverse checking system.
2. Install the extension case oil seal.





3. Using the ST, install the shifter arm oil seal.
ST1 18657AA000 INSTALLER
ST2 18671AA000 OIL SEAL GUIDE





4. Install the oil plate.
5. Select the bearing thrust washer, and then install it to extension case.
6. Apply oil lightly to the outer periphery of bearing cone, and then install it to extension case.





7. Install the shift bracket.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)
8. Install the extension guide, and then install the transfer driven gear.

INSPECTION
1. Make sure there is no damage or crack on extension case. If there is damage or crack, replace the extension case.
2. Check each oil seal and joint part of extension case and transmission case for oil leakage. If there is oil leakage, replace the oil seal and liquid gasket.

ADJUSTMENT
TRANSFER DRIVEN GEAR BEARING THRUST WASHER ADJUSTMENT





1. Using the ST, remove the bearing cone from extension case.
ST 18758AA000 PULLER
2. Remove the thrust washer.





3. Measure the depth "Z" between end of extension case and contact point of bearing cone.
ST 499575500 GAUGE

NOTE: To measure the depth "Z", subtract the thickness of ST [15 mm (0.59 inch)] from the measured value.

4. Remove the transfer driven gear.
5. Remove the center differential.





6. Remove the snap ring and support from selector arm part.
7. Using the ST, remove the neutral set spring and support.
ST1 18756AA000 CLAW





ST2 399863600 PLIERS





8. Lift-up the striking rod and remove the spring pin.





9. Remove the selector arm No. 2 and shifter arm.
10. Install the bearing cone to transfer driven gear.





11. Set the ST.
ST 18831 AA000 GAUGE
12. Rotate the transfer driven gear approx. ten times to get the bearing accustomed.





13. Measure the depth "Y" between end of ST and bearing cone.
ST 18831AA000 GAUGE





14. Calculate the value "t" of transfer driven gear bearing thrust washer using the following equation. t = Z - (100 - Y) - {-0.04 to 0.11 mm (-0.0016 to 0.0043 inch)}





15. Select the nearest thrust washer from the following table, according to the calculated value "t".
Standard clearance between thrust washer end taper roller bearing: -0.04 - 0.11 mm (-0.0016 - 0.0043 inch)

NOTE: Make clearance within standard.





16. Install the selector arm No. 2 and shifter arm.
17. Install a new spring pin.





18. Install the support to neutral set spring.

NOTE: Make sure to install the support in proper direction.





19. Using the ST, install the neutral set spring and support.
ST1 18756AA000 CLAW
ST2 399863600 PLIERS
20. Install the snap ring.
21. Install the center differential.

SELECTING THE TRANSFER DRIVE GEAR THRUST WASHER





1. Measure the height "Z" between end of transmission case and end of ST.
ST 499575500 GAUGE





2. Measure the depth "Y" between end of ST and transfer drive gear.
ST 499575500 GAUGE





3. Calculate the value "t" of transfer drive gear thrust washer using the following equation. t = {Y - 15 mm (1.18 inch)} - {Z - 15 mm (1.18 inch)} -0.45 to 0.65 mm (0.018 to 0.026 inch)





4. Select the nearest thrust washer from the following table, according to the calculated value "t".
Standard clearance between thrust washer end transfer drive gear: 0.45 - 0.65 mm (0.018 - 0.026 inch)
5. Install the selected thrust washer.